KR102504424B1 - Controller for motor and motor assembly having the same - Google Patents

Abstract

An embodiment is a substrate; a controller housing disposed on the substrate; a CM filter unit disposed between the substrate and the controller housing; a DM filter unit disposed under the CM filter unit; a controller cover disposed between the substrate and the DM filter unit; a power module unit disposed between the substrate and the controller cover; and a connector part coupled to the substrate, wherein the power module part includes a power module; and a mold part surrounding the power module, wherein the mold part relates to a controller for a motor including a boss protruding from one side and a motor assembly including the same. Accordingly, it is possible to solve the heat generation problem of the power module unit.

Description

Controller for motor and motor assembly including the same {CONTROLLER FOR MOTOR AND MOTOR ASSEMBLY HAVING THE SAME}

The embodiment relates to a controller for a motor and a motor assembly including the same.

A motor is a device that converts electrical energy into rotational energy by using the force received by a conductor in a magnetic field. Recently, as the use of motors has expanded, the role of motors is becoming more important. In particular, as the electrification of automobiles is rapidly progressing, the demand for motors applied to steering systems, braking systems, and design systems is greatly increasing.

In the case of such a vehicle motor, it may be provided as a motor assembly including a controller capable of controlling the motor.

As a large current is used in the controller, a heating problem has emerged. For example, in the case of a board used for a controller, a DC power circuit, a control circuit, and an inverter circuit are disposed in the board. In addition, as a large current is applied, heat generation occurs in the substrate. Since the size of the substrate must be increased in order to solve this heat generation problem, there is difficulty in miniaturization and weight reduction.

Accordingly, there is a demand for a compact motor assembly capable of solving the problem of heat generation generated in the board.

In addition, since the size of the controller is limited by the user's request, a bus bar designed to secure space for the controller and simplify assembly within the limited size is required. Inventions related to this include United States Patent Application Publication No. US2016/0347353 (2016.12.01.), Patent Publication No. 10-2016-0081675 (2016.07.08.), and United States Patent Application Publication No. US2013/0088128 (2013.04 .11.).

Embodiments provide a controller and motor assembly that can solve the heat generation problem of the power module.

In addition, a controller and motor assembly capable of sharing some parts while miniaturization and weight reduction are provided.

The problem to be solved by the present invention is not limited to the above-mentioned problems, and other problems not mentioned herein will be clearly understood by those skilled in the art from the following description.

According to the embodiment, the task is a substrate; a controller housing disposed on the substrate; a CM filter unit disposed between the substrate and the controller housing; a DM filter unit disposed under the CM filter unit; a controller cover disposed between the substrate and the DM filter unit; a power module unit disposed between the substrate and the controller cover; and a connector part coupled to the substrate, wherein the power module part includes a power module; and a mold part surrounding the power module, and the mold part is achieved by a controller for a motor including a boss protruding from one side.

Here, the power module includes a power module body; a terminal pin coupled to one side of the power module body; and a terminal portion coupled to the other side of the power module body, and an end portion of the terminal pin may be coupled to the substrate.

The terminal unit may include two first power module terminals protruding from the other side of the power module body to the outside of the mold unit; and three second power module terminals, one side of which is respectively connected to the other side of the power module body.

The second power module terminal includes a body having one end connected to the power module body; an end bent from the other end of the body and disposed inside the boss; And it may include a hole formed at the end.

In addition, the boss part may be branched from the mold part into three parts.

Here, the boss portion may protrude toward the substrate, and the other side of the second power module terminal may be exposed to the inside of the boss portion.

And, a space is formed inside the boss part, and the space may be formed in a shape penetrating from a lower part to an upper part.

In addition, a protrusion protruding downward may be further formed at a lower end of the boss portion.

Meanwhile, a width of one side of the mold portion in which the boss portion is formed is smaller than a width of the other side of the mold portion disposed to face each other.

In addition, one side of the first power module terminal protruding outward from the mold part may be disposed to protrude downward.

The power module body may further include a protrusion area protruding from one side, and the protrusion area may be disposed between the first power module terminals.

And, the other side of the first power module terminal may be connected to the protrusion area.

Meanwhile, the controller cover may be formed of a metal material.

According to the embodiment, the task includes a controller for a motor, and a motor, and the controller for the motor includes a substrate; a controller housing disposed on the substrate; a CM filter unit disposed between the substrate and the controller housing; a DM filter unit disposed under the CM filter unit; a controller cover disposed between the substrate and the DM filter unit; a power module unit disposed between the substrate and the controller cover; and a connector part coupled to the substrate, wherein the power module part includes a power module; and a mold part surrounding the power module, wherein the mold part is achieved by a motor assembly including a boss protruding from one side.

And, the motor includes a rotating shaft; a rotor disposed outside the rotating shaft; a stator disposed outside the rotor; a bus bar disposed above the stator; a motor housing accommodating the rotor, the stator, and the bus bar; and a motor cover disposed in an opening of the motor housing, wherein the bus bar includes a bus bar body; and a bus bar terminal, wherein the power module includes a power module body; a terminal pin coupled to one side of the power module body; two first power module terminals disposed to protrude downward from the other side of the power module body; and three second power module terminals, one side of which is respectively connected to the other side of the power module body, and one side of the bus bar terminal may be coupled to a hole of the second power module terminal.

The connector unit may include a first connector and a second connector, and each of the first connector and the second connector may pass through the controller cover.

In addition, one side of the first connector is coupled to the board and the other side is disposed inside any one of three bosses formed on the controller housing, and one side of the second connector is coupled to the board and the other side is disposed on the controller housing. It can be placed inside another one of the three bosses formed in .

In the motor assembly including the controller according to the embodiment, the power module having a high calorific value is brought into close contact with the controller cover formed of a metal material to solve the heat generation problem.

In addition, space utilization and material cost and mold cost can be reduced by arranging the mold part in the power module in an insert injection method.

In addition, by disposing the mold part in the power module in an insert injection method, the size of the power module can be increased to improve the degree of freedom in designing the power module. Furthermore, the increased size of the power module increases the contact area with the controller cover, so that heat dissipation performance can be improved.

In addition, the controller and motor assembly may implement a compact structure by arranging large-sized elements vertically.

In addition, whenever a different type of motor is coupled to the controller, it is possible to share some parts of the controller by replacing only the board together.

In addition, reverse connection of power can be prevented by using a MOSFET disposed on the board. Accordingly, reliability of the stability of the motor assembly may be improved.

Various but beneficial advantages and effects of this embodiment are not limited to the above-described content, and will be more easily understood in the process of describing specific embodiments of this embodiment.

1 is a perspective view showing a motor assembly according to an embodiment,
2 is an exploded perspective view of the motor assembly according to the embodiment in which the power module unit according to the first embodiment is disposed;
3 is a cross-sectional view showing a motor assembly according to an embodiment,
4 is a plan view of a motor assembly according to an embodiment;
5 is a perspective view showing a controller housing of a motor assembly according to an embodiment;
6 is a bottom perspective view showing a controller housing of a motor assembly according to an embodiment;
7 is a perspective view showing a CM filter unit of a motor assembly according to an embodiment;
8 is a bottom perspective view showing a CM filter unit of a motor assembly according to an embodiment;
9 is a diagram showing a second terminal, a 2-1 terminal, a 2-2 terminal, a CM filter, and a first capacitor of a CM filter unit according to an embodiment;
10 is a view showing the arrangement relationship between the first terminal of the controller housing of the motor assembly and the second terminal of the CM filter unit according to the embodiment;
11 is a view showing the arrangement relationship between the first projection of the controller housing of the motor assembly and the first hole of the CM filter unit according to the embodiment;
12 is a view showing a relationship in which a first protrusion of a controller housing of a motor assembly according to an embodiment is fused and fixed to a first hole;
13 is a perspective view showing a DM filter unit of a motor assembly according to an embodiment;
14 is an exploded perspective view showing a DM filter unit of a motor assembly according to an embodiment;
15 is a bottom perspective view showing a DM filter unit of a motor assembly according to an embodiment;
16 is a plan view illustrating a DM filter unit of a motor assembly according to an embodiment;
17 is a perspective view illustrating a third terminal, a 3-1 terminal, a 3-2 terminal, a 3-3 terminal, a DM filter, and a second capacitor of a DM filter unit according to an embodiment;
18 is a bottom perspective view illustrating a third terminal, a 3-1 terminal, a 3-2 terminal, a 3-3 terminal, a DM filter, and a second capacitor of a DM filter unit according to an embodiment;
19 is a view showing coupling of a CM filter unit and a DM filter unit of a motor assembly according to an embodiment;
20 is a perspective view showing a controller cover of a motor assembly according to an embodiment;
21 is a bottom perspective view showing a controller cover of a motor assembly according to an embodiment,
22 is a bottom view showing the controller cover of the motor assembly according to the embodiment,
23 is an enlarged view showing area A of FIG. 3;
24 is a perspective view showing a power module unit according to the first embodiment of the motor assembly according to the embodiment;
25 is a bottom perspective view showing the power module unit according to the first embodiment of the motor assembly according to the embodiment;
26 is an exploded perspective view showing the power module unit according to the first embodiment of the motor assembly according to the embodiment;
27 is a plan view showing the power module unit according to the first embodiment of the motor assembly according to the embodiment;
28 is a side view showing the power module unit according to the first embodiment of the motor assembly according to the embodiment;
29 is a diagram showing a power module according to a first embodiment of a power module unit according to an embodiment;
30 is a view showing a bracket of the power module unit according to the first embodiment;
31 is a diagram showing a fourth terminal of the power module unit according to the first embodiment;
32 is a view showing a substrate of a motor assembly according to an embodiment,
33 is a view showing a first connector of a motor assembly according to an embodiment,
34 is a view showing a second connector of a motor assembly according to an embodiment,
35 is a view showing a bus bar terminal of a motor assembly according to an embodiment;
36 is an exploded perspective view showing a motor according to the embodiment in which the power module unit according to the second embodiment is disposed;
37 is a perspective view showing a power module unit according to a second embodiment of a motor assembly according to an embodiment;
38 is a bottom perspective view showing a power module unit according to a second embodiment of a motor assembly according to an embodiment;
39 is a plan view showing a power module unit according to a second embodiment of a motor assembly according to an embodiment;
40 is a diagram showing a power module of the power module unit according to the second embodiment.

Since the secondary invention can make various changes and have various embodiments, specific embodiments will be illustrated and described in the drawings. However, this is not intended to limit the present invention to specific embodiments, and should be understood to include all modifications, equivalents, and substitutes included in the spirit and scope of the present invention.

Terms including ordinal numbers such as second and first may be used to describe various components, but the components are not limited by the terms. These terms are only used for the purpose of distinguishing one component from another. For example, a second element may be termed a first element, and similarly, a first element may be termed a second element, without departing from the scope of the present invention. The terms and/or include any combination of a plurality of related recited items or any of a plurality of related recited items.

It is understood that when an element is referred to as being "connected" or "connected" to another element, it may be directly connected or connected to the other element, but other elements may exist in the middle. It should be. On the other hand, when an element is referred to as “directly connected” or “directly connected” to another element, it should be understood that no other element exists in the middle.

In the description of the embodiment, in the case where one component is described as being formed “on or under” another component, the upper (above) or lower (below) (on or under) includes both those formed by direct contact between two components or by indirectly placing one or more other components between the two components. In addition, when expressed as 'on or under', it may include the meaning of not only the upward direction but also the downward direction based on one component.

Terms used in this application are only used to describe specific embodiments, and are not intended to limit the present invention. Singular expressions include plural expressions unless the context clearly dictates otherwise. In this application, the terms "include" or "have" are intended to designate that there is a feature, number, step, operation, component, part, or combination thereof described in the specification, but one or more other features It should be understood that the presence or addition of numbers, steps, operations, components, parts, or combinations thereof is not precluded.

Unless defined otherwise, all terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with the meaning in the context of the related art, and unless explicitly defined in this application, it should not be interpreted in an ideal or excessively formal meaning. don't

Hereinafter, the embodiments will be described in detail with reference to the accompanying drawings, but the same or corresponding components regardless of reference numerals are given the same reference numerals, and overlapping descriptions thereof will be omitted.

1 is a perspective view showing a motor assembly according to an embodiment.

The motor assembly 1 according to the embodiment may include a controller 2 and a motor 3 according to the embodiment. Here, the controller 2 is a motor controller that controls the motor 3 .

Here, the motor 3 may be detachably disposed under the controller 2 . Therefore, even if some parts of the controller 2 are shared, various motors 3 can be connected to the controller 2. At this time, a board may be disposed between the controller 2 and the motor 3 to be replaceable. Accordingly, by replacing only the substrate together whenever a different type of motor 3 is coupled, some parts of the controller 2 can be shared.

2 is an exploded perspective view of a motor assembly according to an embodiment in which a power module unit according to the first embodiment is disposed, FIG. 3 is a cross-sectional view showing the motor assembly according to the embodiment, and FIG. 4 is a plan view of the motor assembly according to the embodiment. am. Here, FIG. 3 may be a cross-sectional view taken along line A-A of FIG. 1 .

1 to 3, the controller 2 includes a controller housing 100, a CM filter unit 200, a DM filter unit 300, a controller cover 400, and a power module unit according to the first embodiment. 500, a substrate 600, and a connector part. Here, the connector unit may include a first connector 700 and a second connector 800 .

The connector part may pass through the controller cover 400 . At this time, the connector part may pass through the controller cover 400 to be spaced apart from the outside of the power module part 500 . For example, one side of each of the first connector 700 and the second connector 800 disposed through the controller cover 400 may be disposed on the board 600 . As shown in FIG. 4, the other side of the first connector 700 is disposed inside any one of the three bosses formed in the controller housing 100, and the other side of the second connector 800 is any one of the three bosses. Can be placed inside one.

The controller 2 receives power from an external connector and transfers power to the board 600 through the CM filter unit 200 and the DM filter unit 300 . In addition, power for which reverse connection is prevented in the substrate 600 is transferred to the DM filter unit 300 and then supplied to the power module unit 500 and the substrate 600 .

The controller housing 100 and the controller cover 400 disposed in the opening of the controller housing 100 may form the outer shape of the controller 2 . Here, the controller housing 100 may be disposed on the substrate 600.

An accommodation space may be formed by combining the controller housing 100 and the controller cover 400 . The CM filter unit 200 and the DM filter unit 300 may be disposed in the accommodation space.

5 is a perspective view showing a controller housing of a motor assembly according to an embodiment, and FIG. 6 is a bottom perspective view showing a controller housing of a motor assembly according to an embodiment.

Referring to FIGS. 5 and 6 , the controller housing 100 may include a controller housing body 110 and a first terminal 120 . Here, the controller housing body 110 may be referred to as a first body. Also, the first terminal 120 may be called a controller housing terminal.

The controller housing body 110 may be formed in a tubular shape to form the accommodation space therein. An opening may be formed in the controller housing body 110 for disposing the CM filter unit 200 and the DM filter unit 300 .

A first boss 111 , a second boss 112 , a third boss 113 , a plurality of first protrusions 114 , and a first protrusion 115 may be formed on the controller housing body 110 . Here, the first boss 111, the second boss 112, the third boss 113, the first protrusion 114, and the first protrusion 115 may be integrally formed with the controller housing body 110. .

The first boss 111 , the second boss 112 , and the third boss 113 may protrude from the top of the controller housing body 110 . In this case, the first boss 111, the second boss 112, and the third boss 113 may be spaced apart from each other.

A space may be formed inside each of the first boss 111, the second boss 112, and the third boss 113, and the first boss 111, the second boss 112, and the third boss 113 ) may be connected to each of external connectors (not shown) capable of transmitting and receiving power or signals from the outside. Accordingly, each of the first boss 111, the second boss 112, and the third boss 113 may be formed in various shapes according to the shape of the external connector.

As shown in FIG. 6 , the plurality of first protrusions 114 may be formed to protrude downward from the lower inner surface 116 of the controller housing body 110 . Accordingly, the CM filter unit 200 may be coupled to the lower portion of the controller housing 100 through the first protrusion 114 .

The first protrusion 115 may be formed to protrude downward from an end of the controller housing body 110 . Also, the first protrusion 115 may be coupled to the controller cover 400 .

As shown in FIG. 5 , the first terminal 120 may be provided in two.

The first terminal 120 may be disposed on the controller housing body 110 through an insert injection method. Here, the first terminal 120 may be formed of a metal material. For example, the first terminal 120 may be formed by press-working a sheet metal such as a copper plate.

Power may be applied to the first terminal 120 through an external connector coupled to the first boss 111 .

4 and 6, one side of the first terminal 120 is disposed inside the first boss 111, and the end 121 of the other side is downward from the inner surface 116 of the controller housing body 110. It can be arranged to protrude into. As shown in FIG. 6 , the first terminal 120 may be fixed to the inside of the controller housing body 110 by a fastening member 4 such as a bolt or screw.

Meanwhile, the controller housing body 110 including the first boss 111, the second boss 112, and the third boss 113 may be formed of a synthetic resin material. Accordingly, the controller housing body 110 may be formed in various shapes according to the design, and it is possible to reduce the weight of the motor assembly 1.

Figure 7 is a perspective view showing the CM filter unit of the motor assembly according to the embodiment, Figure 8 is a bottom perspective view showing the CM filter unit of the motor assembly according to the embodiment, Figure 10 is a first controller housing of the motor assembly according to the embodiment 11 is a view showing the arrangement relationship between the terminal and the second terminal of the CM filter unit, and FIG. 11 is a view showing the arrangement relationship between the first projection of the controller housing of the motor assembly and the first hole of the CM filter unit according to the embodiment, and FIG. It is a view showing a relationship in which the first protrusion of the controller housing of the motor assembly according to is fused and fixed to the first hole.

The CM filter unit 200 may be disposed above the DM filter unit 300 . The CM filter unit 200 may be disposed between the controller housing 100 and the substrate 600. At this time, the CM filter unit 200 may be disposed below the inner surface 116 of the controller housing 100.

7 to 9, the CM filter unit 200 includes a CM filter unit body 210, a second terminal 220, a 2-1 terminal 230, a 2-2 terminal 240, and a CM filter unit 210. (CM, Common Mode) filter 250 and two first capacitors 260 may be included. In addition, first holes 225 , 235 , and 245 may be formed in the second terminal 220 , the 2-1 terminal 230 , and the 2-2 terminal 240 , respectively. Here, it may be referred to as the CM filter unit body 210, and the first capacitor 260 may be referred to as a CM filter unit capacitor. Also, the first holes 225, 235, and 245 may be referred to as fixing holes.

Meanwhile, the CM filter body 210 may be made of a synthetic resin material, and the second terminal 220, the 2-1 terminal 230 and the 2-2 terminal 240 may be made of a metal material. . Accordingly, the second terminal 220, the 2-1 terminal 230, and the 2-2 terminal 240 may be disposed on the CM filter body 210 through the insert injection method. In this case, each of the second terminal 220, the 2-1 terminal 230, and the 2-2 terminal 240 may be preferentially formed by press-working a sheet metal such as a copper plate.

The CM filter body 210 may be formed in a U-shape.

A second hole 211 may be formed in the CM filter body 210 . Here, the second hole 211 may be called a guide hole.

The first protrusion 114 of the controller housing 100 may be disposed in the second hole 211 . Accordingly, since the CM filter unit body 210 can be disposed on the controller housing 100 by inserting the second hole 211 into the first protrusion 114, the assembly position of the CM filter unit 200 is imprisoned Furthermore, the combination of the first protrusion 114 and the second hole 211 prevents the flow of the CM filter unit 200 in the horizontal direction.

One side of the second terminal 220 is in contact with the other end 121 of the first terminal 120, and the other side is in contact with the CM filter 250 to be electrically connected. Here, two second terminals 220 may be provided corresponding to the number of first terminals 120 .

The second terminal 220 includes a second body 221 disposed horizontally, a second frame 222 protruding downward from one end of the second body 221, and the other end of the second body 221. It may include a second bent portion 223 formed by bending, a second end portion 224 and a first hole 225 .

The second frame 222, which is one end of the second terminal 220 in contact with the first terminal 120, may be formed by bending one side of the second body 221 downward. As shown in FIG. 10, one end 121 of the first terminal 120 disposed to protrude downward from the inner surface 116 and the second frame 222 of the second terminal 220 bent downward are come into contact At this time, contact force between one end 121 of the first terminal 120 and the second frame 222 of the second terminal 220 may be improved through a fusing process.

The second bent portion 223, which is one of the other ends of the second terminal 220, is connected to the first wire 251 disposed in the CM filter 250. To this end, the second bent portion 223 formed on the other side of the second body 221 may be formed in a hook shape, and the other side of the first wire 251 and the second terminal 220 through the fusing process is electrically can be connected to Here, the first wire 251 may be referred to as a first CM filter wire.

The second end 224 branched from the other side of the second terminal 220 is electrically connected to the second wire 261 disposed in the first capacitor 260 . For example, the second end 224 may be formed in a shape in which two protrusions are spaced apart from each other, and as shown in FIG. 8 , a second wire 261 may be disposed between the protrusions. In this case, the second wire 261 and the second end 224 of the second terminal 220 may be electrically connected through the fusing process. Here, the second wire 261 may be called a second CM filter wire.

Referring to FIGS. 7 to 9 , a first hole 225 may be formed in the second terminal 220 .

As shown in FIG. 11 , the first protrusion 114 of the controller housing 100 may be disposed in the first hole 225 . Accordingly, the first hole 225 may be coupled to the first protrusion 114 by inserting the first hole 225 into the first protrusion 114 .

Then, as shown in FIG. 12 , the end of the first protrusion 114 may be fused to the second terminal 220 by heating. Accordingly, the CM filter unit 200 may be fixed to the controller housing 100. Here, since the first protrusion 114 is formed of a synthetic resin material and the second terminal 220 is formed of a metal material, thermal fusion is possible.

One side of the 2-1 terminal 230 is bent toward the DM filter unit 300, and the other side contacts and is electrically connected to the CM filter 250. Here, two 2-1 terminals 230 may be provided.

The 2-1 terminal 230 includes a 2-1 body 231 disposed horizontally, a 2-1 frame 232 protruding downward from one end of the second body 221, and a second body ( 221) may include a 2-1 bent portion 233 formed by bending the other end and a first hole 235.

The 2-1 frame 232 may be formed by bending one end of the 2-1 body 231 downward. The 2-1 frame 232 , which is one end of the 2-1 terminal 230 bent downward, may be coupled to the third terminal 320 of the DM filter unit 300 . In this case, two second protrusions 234 may be spaced apart from each other on the 2-1 frame 232 . Accordingly, coupling force and contact force between the second protrusion 234 and the third terminal 320 may be improved.

The other side of the 2-1 terminal 230 is connected to the first wire 251 disposed in the CM filter 250. To this end, the 2-1 bent portion 233 of the 2-1 terminal 230 may be formed in a hook shape, and the first wire 251 and the 2-1 terminal 230 are formed through a fusing process. The other side may be electrically connected.

Referring to FIGS. 7 to 9 , a first hole 235 may be formed in the 2-1 terminal 230 .

As shown in FIG. 11 , the first protrusion 114 of the controller housing 100 may be disposed in the first hole 235 . Accordingly, the first hole 235 may be coupled to the first protrusion 114 by inserting the first hole 235 into the first protrusion 114 .

Then, as shown in FIG. 12 , the end of the first protrusion 114 may be fused to the 2-1 terminal 230 by heating. Accordingly, the CM filter unit 200 may be fixed to the controller housing 100.

The 2-2 terminal 240 may perform a grounding function.

One side of the 2-2 terminal 240 is bent toward the DM filter unit 300, and the other side contacts and is electrically connected to the first capacitor 260. Here, the other end 242 of the 2-2nd terminal 240 may be branched to be connected to the first capacitor 260 provided in two.

The 2-2 terminal 240 includes a 2-2 body 241 disposed horizontally, a 2-2 frame 242 protruding downward from one end of the second body 241, and a 2-2 It may include an end 244 and a first hole 245 .

The 2-2 frame 242 may be formed by bending one side of the 2-2 body 241 downward. The 2-2 frame 242 , which is an end of one side of the 2-2 terminal 240 bent downward, may be coupled to the 3-3 terminal 350 of the DM filter unit 300 . At this time, two second protrusions 243 may be further disposed to be spaced apart from each other on the 2-2nd frame 242 . Accordingly, coupling force and contact force between the second protrusion 243 and the third and fourth terminals 360 may be improved.

The other side of the 2-2 terminal 240 is electrically connected to the second wire 261 disposed in the first capacitor 260. To this end, the 2-2nd end 244, which is the other end of the 2-2nd terminal 240, may be formed in a shape in which two protrusions are spaced apart, and as shown in FIG. 8, between the protrusions. The second wire 261 may be disposed on. At this time, the second wire 261 and the other side of the 2-2 terminal 240 may be electrically connected through the fusing process.

Referring to FIGS. 7 to 9 , a first hole 245 may be formed in the 2-2 terminal 240 .

As shown in FIG. 11 , the first protrusion 114 of the controller housing 100 may be disposed in the first hole 245 . Accordingly, the first hole 245 may be coupled to the first protrusion 114 by inserting the first hole 245 into the first protrusion 114 .

Then, as shown in FIG. 12 , the end of the first protrusion 114 may be fused to the 2-2 terminal 240 by heating. Accordingly, the CM filter unit 200 may be fixed to the controller housing 100.

The CM filter 250 may be disposed between the second terminal 220 and the 2-1 terminal 230 . At this time, the CM filter 250 is disposed on the upper part of the CM filter unit body 210 and may be disposed between two legs of the CM filter unit body 210 that are horizontally disposed apart from each other.

The CM filter 250 can reduce common mode noise. For example, the second terminal 220 electrically connected to the first terminal 120 is used as a power line, and can reduce common mode noise caused by a common mode current component among conduction noise generated by being used as the power line. there is.

As shown in FIG. 7, a plurality of first wires 251 are disposed in the CM filter 250, and the first wires 251 are connected to the second terminal 220 and the 2-1 terminal ( 230) can be electrically connected to each other.

The first capacitor 260 may be disposed under the CM filter body 210 . In this case, the plurality of second wires 261 disposed on the first capacitor 260 may be electrically connected to the second terminal 220 and the 2-2 terminal 240, respectively.

13 is a perspective view showing a DM filter unit of a motor assembly according to an embodiment, FIG. 14 is an exploded perspective view showing a DM filter unit of a motor assembly according to an embodiment, and FIG. 15 is a bottom view showing a DM filter unit of a motor assembly according to an embodiment. 16 is a plan view illustrating a DM filter unit of a motor assembly according to an embodiment, and FIG. 17 is a third terminal, a 3-1 terminal, a 3-2 terminal, and a 3-3 DM filter unit according to an embodiment. 18 is a diagram showing a terminal, a DM filter, and a second capacitor, and FIG. 18 is a third terminal, a 3-1 terminal, a 3-2 terminal, a 3-3 terminal, a DM filter, and a second terminal of a DM filter unit according to an embodiment. FIG. 19 is a bottom perspective view showing a capacitor, and FIG. 19 is a view showing coupling of a CM filter unit and a DM filter unit of a motor assembly according to an embodiment.

The DM filter unit 300 may be disposed above the controller cover 400 . In this case, the DM filter unit 300 may be disposed under the CM filter unit 200 .

13 to 17, the DM filter unit 300 includes a DM filter unit body 310, a third terminal 320, a 3-1 terminal 330, a 3-2 terminal 340, A 3-3 terminal 350, a 3-4 terminal 360, a DM (Differential Mode) filter 370, and three second capacitors 380 may be included. Here, the DM filter unit body 310 may be referred to as a third body, and the second capacitor 380 may be referred to as a DM filter unit capacitor.

The DM filter unit body 310 may be formed of a synthetic resin material, and includes a third terminal 320, a 3-1 terminal 330, a 3-2 terminal 340, a 3-3 terminal 350, The third and fourth terminals 360 may be formed of a metal material. Accordingly, the third terminal 320, the 3-1 terminal 330, the 3-2 terminal 340, the 3-3 terminal 350, and the 3-4 terminal 360 through the insert injection method. may be disposed on the body 310 of the DM filter unit. At this time, each of the third terminal 320, the 3-1 terminal 330, the 3-2 terminal 340, the 3-3 terminal 350, and the 3-4 terminal 360 is a sheet metal such as a copper plate. It may be preferentially molded by press working.

A fourth hole 311 and a plurality of second protrusions 312 may be formed in the DM filter unit body 310 . Here, the fourth hole 311 may be called a fastening hole.

The DM filter unit 300 may be fixed to the controller cover 200 by the fastening member 4 disposed in the fourth hole 311 .

The second protrusion 312 may be formed to protrude downward from the DM filter body 310 . Here, the second protrusion 312 may be integrally formed with the DM filter body 310 .

The second protrusion 312 may be disposed through the controller cover 400 . Accordingly, the third terminal 320, the 3-1 terminal 330, the 3-2 terminal 340, and the 3-3 terminal 350 are respectively disposed inside the second protrusion 312. ) may be insulated from the controller cover 400.

The third terminal 320 electrically connects the 2-1 terminal 230 and the substrate 600 . At this time, the third terminal 320 may be provided in two. Also, one area of the third terminal 320 may pass through the controller cover 400 . To this end, a hole may be formed in the controller cover 400 .

The third terminal 320 may include a third body 321 disposed horizontally, a third frame 322 protruding downward from one end of the third body 321, and a third hole 323. there is.

A third hole 323 may be formed in each of the third body 321 . Here, the third hole 323 may be called a coupling hole.

As shown in FIG. 19 , the 2-1 frame 232 , which is one end of the 2-1 terminal 230 , may be coupled to the third hole 323 .

If the third hole 323 is formed in two, the second protrusion 234 formed on the 2-1 frame 232 may be combined. Accordingly, bonding force and contact force between the 2-1 terminal 230 and the third terminal 320 may be improved.

One area of the third terminal 320 may be bent toward the substrate 600 . For example, the third frame 322, which is one end of the bent third terminal 320, may be formed by bending downward.

The third frame 322 of the third terminal 320 may protrude from the end of the second protrusion 312 . At this time, the second protrusion 312 is arranged to surround one area of the third frame 322 so that the third terminal 320 is insulated from the controller cover 400 .

Also, an end of the third frame 322 exposed from the second protrusion 312 may be fixed to the substrate 600 through soldering.

One side of the 3-1 terminal 330 is connected to the substrate 600, and the other side is connected to the DM filter 370. Accordingly, the 3-1 terminal 330 electrically connects the DM filter 370 and the substrate 600. At this time, one area of the 3-1 terminal 330 may pass through the controller cover 400 . To this end, a hole may be formed in the controller cover 400 .

The 3-1 terminal 330 includes a 3-1 body 331 disposed horizontally, a 3-1 frame 332 protruding downward from one end of the 3-1 body 331, and a third -1 may include a 3-1 end 333 disposed on the other side of the body 331 .

One area of the 3-1 body 331 may be bent toward the substrate 600 . For example, the 3-1 frame 332, which is one end of the bent 3-1 terminal 330, may be formed by bending one side of the 3-1 body 331 downward.

The 3-1 frame 332 , which is an end of the 3-1 frame 332 , may be disposed to protrude from the end of the second protrusion 312 . At this time, the second protrusion 312 is arranged to surround a region of the 3-1 frame 332 so that the 3-1 terminal 330 is insulated from the controller cover 400 .

Also, an end of the 3-1 frame 332 exposed from the second protrusion 312 may be fixed to the substrate 600 through soldering.

The 3-1st end 333 , which is the other end of the 3-1st terminal 330 , is electrically connected to the third wire 371 disposed in the DM filter 370 . To this end, the 3-1-th end 333 may be formed in a shape in which two protrusions are spaced apart, and as shown in FIG. 13, a third wire 371 may be disposed between the protrusions. . In this case, the third wire 371 and the 3-1 end 333 of the 3-1 terminal 330 may be electrically connected through the fusing process.

The 3-2 terminal 340 electrically connects the DM filter 370, the second capacitor 380, the power module unit 500, and the substrate 600.

The 3-2 terminal 340 includes a 3-2 body 341 disposed horizontally, a 3-2 frame 342 protruding downward from the 3-2 body 341, and a 3-2 body A 3-2 end portion 343 protruding upward from 341 may be included. Here, the 3-2 frame 342 includes the 3-2-1 frame 342a having an end coupled to the power module unit 500 and the 3-2-2 frame having an end coupled to the substrate 600 ( 342b). The 3-2 end part 343 includes the 3-2-1 end part 343a coupled to the DM filter 370 and the 3-2-2 end part 343b coupled to the second capacitor 380. can include

One area of the 3-2nd body 341 may be bent downward. For example, the 3-2 frame 342, which is one end of the bent 3-2 terminal 340, may be formed by bending one side of the 3-1 body 331 downward.

Accordingly, an end of the 3-2-1 frame 342a, which is one of the 3-2 frames 342, may be coupled to the power module unit 500. Also, an end of the 3-2-2 frame 342b, which is another one of the 3-2 frames 342, may be coupled to the substrate 600. At this time, the length of the 3-2-1 frame (342a) is smaller than the length of the 3-2-2 frame (342b).

The 3-2 frame 342 of the 3-2 terminal 340 may pass through the controller cover 400 . To this end, a hole may be formed in the controller cover 400 .

Meanwhile, the 3-2 frame 342 of the 3-2 terminal 340 may protrude from the end of the second protrusion 312 . At this time, the second protrusion 312 is disposed to surround one area of the 3-2 frame 342, so that the 3-2 terminal 340 disposed through the controller cover 400 is connected to the controller cover 400. to be insulated from

Also, an end of the 3-2-2 frame 342b exposed from the second protrusion 312 may be fixed to the substrate 600 through soldering.

The 3-2-1 end portion 343a, which is one of the other ends of the 3-2 terminal 340, is electrically connected to the third wire 371 disposed in the DM filter 370. To this end, the 3-2-1 end portion 343a may be formed in a shape in which two protrusions are spaced apart, and as shown in FIG. 13, a third wire 371 may be disposed between the protrusions. can In this case, the third wire 371 and the 3-2-1 end portion 343a of the 3-1 terminal 330 may be electrically connected through the fusing process. Here, the third wire 371 may be called a first DM filter wire.

The 3-2-2 end portion 343b, which is the other end of the other end of the 3-2 terminal 340, is electrically connected to the fourth wire 381 disposed in the second capacitor 380. For example, the 3-2-2 end portion 343b may be formed in a shape in which two protrusions are spaced apart, and as shown in FIG. 13, a fourth wire 381 may be disposed between the protrusions. there is. In this case, the fourth wire 381 and the 3-2-2 end portion 343b of the 3-1 terminal 330 may be electrically connected through the fusing process. Here, the fourth wire 381 may be referred to as a second DM filter wire.

The 3-3 terminal 350 electrically connects the second capacitor 380 , the power module unit 500 and the substrate 600 .

The 3-3 terminal 350 includes a 3-3 body 351 disposed horizontally, a 3-3 frame 352 protruding downward from the 3-3 body 351, and a 3-3 body. A 3-3 end portion 353 protruding upward from 351 may be included.

One area of the 3-3rd body 351 may be bent downward. For example, the 3-3 frame 352, which is one end of the bent 3-3 terminal 350, may be formed by bending one side of the 3-1 body 331 downward.

Here, the 3-3 frame 352 includes the 3-3-1 frame 352a having an end coupled to the substrate 600 to receive power, and a third frame 352a having an end coupled to the substrate 600 to transmit power. -3-2 frame 352b and the 3-3-3 frame 352c having ends coupled to the power module unit 500 to transmit power may be included.

At this time, the length of the 3-3-3 frame 352c is smaller than the length of the 3-3-1 frame 352a. And, the length of the 3-3-1 frame (352a) may be the same as the length of the 3-3-2 frame (352b).

Also, the 3-3 frame 352 of the 3-3 terminal 350 may pass through the controller cover 400 . To this end, a hole may be formed in the controller cover 400 .

Also, the 3-3 frame 352 of the 3-3 terminal 350 may protrude from the end of the second protrusion 312 . At this time, the second protrusion 312 is disposed to surround one area of the 3-3 frame 352, so that the 3-3 terminal 350 passing through the controller cover 400 is connected to the controller cover 400. to be insulated from

Also, an end of the 3-3 frame 352 exposed from the second protrusion 312 may be fixed to the substrate 600 through soldering.

The 3-3 end portion 353 , which is the other end of the 3-3 terminal 350 , is electrically connected to the fourth wire 381 disposed in the second capacitor 380 . For example, the 3-3 end portion 353 may be formed in a shape in which two protrusions are spaced apart from each other, and as shown in FIG. 13 , a fourth wire 381 may be disposed between the protrusions. In this case, the fourth wire 381 and the 3-3 end portion 353 of the 3-1 terminal 330 may be electrically connected through the fusing process.

The 3-4 terminal 360 may be electrically connected to the 2-2 terminal 240 and the controller cover 400 .

The 3-4 terminal 360 may be formed by cutting a region of the 3-3 terminal 350 . For example, when the 3-3 terminal 350 is placed on the DM filter body 310 through the insert injection method, a region of the 3-3 terminal 350 is cut by pressing, thereby cutting the 3-4 terminal. (360) can be formed.

The 3-4 terminal 360 includes a 3-4 body 361 disposed horizontally, a 3-4 frame 362 protruding downward from the 3-4 body 361, and a 3-4 body. 3-4 end portions 363 protruding horizontally from 361 may be included.

One area of the 3-4 body 361 may be bent downward. For example, the 3-4 frame 362, which is one end of the bent 3-4 terminal 360, may be formed by bending one side of the 3-4 body 361 downward. And, by bending the end of the 3-4 frame 362 horizontally, the end of the 3-4 frame 362 can be in contact with the controller cover (400). Accordingly, the 3-4 frames 362 may perform grounding.

As shown in FIG. 18 , the third and fourth ends 363 may be provided as a single protrusion. Accordingly, as shown in FIG. 19 , the third-fourth end portion 363 may be coupled with the second protrusion 243 of the second-second frame 242 .

The DM filter 370 may be disposed between the 3-1 terminal 330 and the 3-2 terminal 340 .

The DM filter 370 can reduce differential mode noise. For example, the 3-1 terminal 330 and the 3-2 terminal 340 can be used as a power line, and among the conduction noise generated by being used as the power line, the common mode noise caused by the differential mode current component can be reduced. can be reduced

A plurality of third wires 271 are disposed in the DM filter 370, and the third wires 271 may be electrically connected to the 3-1 terminal 330 and the 3-2 terminal 340, respectively.

The second capacitor 380 may be disposed above the DM filter body 310 . In this case, the plurality of fourth wires 281 disposed in the second capacitor 380 may be electrically connected to the 3-2 terminal 340 and the 3-3 terminal 350, respectively.

20 is a perspective view showing a controller cover of a motor assembly according to an embodiment, FIG. 21 is a bottom perspective view showing a controller cover of a motor assembly according to an embodiment, and FIG. 22 is a bottom view showing a controller cover of a motor assembly according to an embodiment. FIG. 23 is an enlarged view showing area A of FIG. 3 .

The controller cover 400 may be disposed in the opening of the controller housing 100 . The controller cover 400 may be disposed between the DM filter unit 300 and the substrate 600 .

20 to 22, the controller cover 400 includes a controller cover body 410 disposed in an opening of the controller housing 100 and a third protrusion 420 protruding downward from the controller cover body 410. can include Also, the controller cover 400 may further include a sealing member 430 and an O-ring 440. Here, the controller cover body 410 may be referred to as a fourth body.

The controller cover body 410 and the third protrusion 420 may be integrally formed. Accordingly, the controller cover 400 may be formed of a metal material. For example, the controller cover 400 may be formed of an aluminum material having good thermal conductivity through a die casting method.

The controller cover body 410 may be formed in a plate shape.

The upper surface 411 of the controller cover body 410 may be in contact with the end of the third and fourth frames 362 . Accordingly, the controller cover body 410 formed of a metal material may perform grounding. At this time, the third protrusion 420 may come into contact with the motor housing 10 of the motor 3 .

A first groove 412 may be formed along an edge of the upper surface 411 of the controller cover body 410 . In this case, the first groove 412 may be formed to correspond to the shape of the first protrusion 115 of the controller housing 100 . Accordingly, the first protrusion 115 may be coupled to the first groove 412 . Here, the first groove 412 may be called a coupling groove.

The first groove 412 may be formed in two. Accordingly, the bonding strength and airtightness of the controller housing 100 and the controller cover 400 are improved.

A sealing member 430 may be further disposed in the first groove 412 . As shown in FIG. 23 , the sealing member 430 is disposed between the first protrusion 115 and the first groove 412 to further improve airtightness.

In addition, a plurality of fifth holes 413 are formed in the controller cover body 410 . The fifth hole 413 may be formed to pass through the controller cover body 410 in a vertical direction. Accordingly, frames of the first connector 700 , the second connector 800 , and the third terminal 320 may pass through the controller cover body 410 through the fifth hole 413 . Here, the fifth hole 413 may be called a through hole.

A second groove 415 may be formed on the lower surface 414 of the controller cover body 410 . Here, the second groove 415 may be called an arrangement groove.

Further, a protrusion protruding downward may be further disposed on the lower surface of the controller cover body 410 . And, the protrusion may be integrally formed with the controller cover body 410 . Also, the protrusion may guide the arrangement of the power module unit 500 .

The third protrusion 420 may protrude downward from the controller cover body 410 . And, the third protrusion 420 may be formed in a cylindrical shape.

The third protrusion 420 may be disposed inside the motor housing 10 of the motor 3 . At this time, the outer circumferential surface of the third protrusion 420 contacts the inner circumferential surface of the motor housing 10 to perform grounding. Here, the motor housing 10 may be referred to as a second housing.

A third groove 421 may be formed along an outer circumferential surface of the third protrusion 420 . An O-ring 440 may be disposed in the third groove 421 . Here, the third groove 421 may be called an O-ring groove.

As shown in FIG. 23 , the O-ring 440 may improve airtightness between the inner circumferential surface of the motor housing 10 and the third protrusion 420 .

24 is a perspective view showing a power module unit according to a first embodiment of a motor assembly according to an embodiment, and FIG. 25 is a bottom perspective view showing a power module unit according to a first embodiment of a motor assembly according to an embodiment, and FIG. 26 is It is an exploded perspective view showing the power module part according to the first embodiment of the motor assembly according to the embodiment, Figure 27 is a plan view showing the power module part according to the first embodiment of the motor assembly according to the embodiment, Figure 28 is a 29 is a side view showing the power module according to the first embodiment of the motor assembly according to the first embodiment, FIG. 29 is a view showing the power module according to the first embodiment, and FIG. 30 is the power module according to the first embodiment It is a drawing showing the bracket of the module part.

The power module unit 500 according to the first embodiment transmits a signal capable of controlling the motor 3 . The power module unit 500 may be disposed between the controller cover 400 and the substrate 600 .

24 to 27 , the power module unit 500 may include a power module 510 and a bracket 520.

The power module 510 transmits a signal capable of controlling the motor 3. Here, an automotive power module (APM) may be used as the power module 510 . Accordingly, the power module 510 has a higher calorific value than other configurations of the controller 2 .

The power module 510 includes a power module body 511, a plurality of first pins 512 disposed to protrude downward from one side of the power module body 511, and a plurality of first pins 512 to protrude downward from the other side of the power module body 511. It may include five terminal pins 513 disposed thereon. And, the power module 510 may further include a fourth groove 514 .

As shown in FIG. 28 , the first pin 512 and the terminal pin 513 may face each other and be spaced apart. The end of the first pin 512 is coupled to the substrate 600 to receive a signal from the substrate 600 . In this case, the first pin 512 may be fixed to the board 600 through soldering. Here, the first pin 512 may be referred to as a power module pin. And the terminal pin 513 may be called a power module terminal.

Referring to FIG. 25 , the terminal pin 513 may include a first terminal pin 513a and a second terminal pin 513b.

The three first terminal pins 513a may be electrically connected to the fourth terminal 522 of the bracket 520 . Accordingly, power may be supplied to the motor 3 through the fourth terminal 522 . Here, the fourth terminal 522 may be referred to as a controller terminal.

Each of the two second terminal pins 513b is the 3-2-1 frame 342a of the 3-2 terminal 340 and the 3-3-3 frame 352c of the 3-3 terminal 350 It is electrically connected to and receives power.

When the power module 510 is placed on the bracket 520, the concavely formed fourth groove 514 guides the assembly of the power module 510. Here, the fourth groove 514 may be called a guide groove.

As shown in FIG. 27 , two fourth grooves 514 may be formed on both sides of the power module body 511 . Also, the fourth groove 514 may be disposed on an imaginary line L passing through the power module body 511 .

Meanwhile, the power module 510 may further include a third protrusion 515 . Here, the third protrusion 515 may be referred to as a coupling protrusion.

Referring to FIG. 29 , the third protrusion 515 may be formed to protrude downward from an end of the first terminal pin 513a. For example, the third protrusion 515 may protrude in the same direction as the protruding direction of the first terminal pin 513a. Here, an end of the third protrusion 515 may be coupled to the substrate 600 .

An end of the third protrusion 515 may be fixed to the substrate 600 through soldering. Accordingly, the sensor disposed on the board 600 may check whether a signal is transmitted to the motor 3 through the third protrusion 515 . In addition, the board 600 may shut off the motor 3 by confirming a signal to the motor 3 .

As shown in FIG. 29 , the width W1 of the third protrusion 515 is smaller than the width W2 of the first terminal pin 513a. Accordingly, the third protrusion 515 can be easily disposed and fixed to the substrate 600 . At this time, the width W1 of the third protrusion 515 influences the space occupied by the substrate 600 and the amount of soldering.

The bracket 520 adheres the power module 510 to the lower surface 414 of the controller cover 400. At this time, a fastening member 4 such as a bolt may be used. Accordingly, heat generated in the power module 510 is conducted to the controller cover 400, and the conducted heat is discharged to the outside through the motor housing 10 of the motor 3. That is, the heat dissipation effect of the controller 2 can be increased by the controller cover 400 formed of a metal material.

The bracket 520 may include a bracket body 521 and a fourth terminal 522 . Here, the bracket body 521 may be formed of a synthetic resin material, and the fourth terminal 522 may be formed of a metal material. Accordingly, the fourth terminal 522 may be disposed on the bracket body 521 through an insert injection method. Here, the bracket body 521 may be referred to as a sixth body.

The bracket body 521 includes a cavity 523 formed in the bracket body 521, a fourth boss 524, a plate 525, a hook 526 disposed on the bracket body 521 spaced apart from each other, and a fourth protrusion ( 527) and a fourth protrusion 528. Here, the fourth boss 524 , the plate 525 , the hook 526 , the fourth protrusion 527 , and the fourth protrusion 528 may be integrally formed with the bracket body 521 . Here, the fourth boss 524 may be called a bracket boss or a boss part. And, the plate 525 may be called a support.

As shown in FIG. 26 , the power module body 511 of the power module 510 may be disposed in the cavity 523 .

The three fourth bosses 524 may be formed to protrude downward from the bracket body 521 . A space may be formed inside each of the fourth bosses 524 , and one side of the fourth terminal 522 may be disposed inside the fourth boss 524 .

And, each of the fourth bosses 524 guides the coupling of the motor 3 with one area of the bus bar terminal 62. Accordingly, one area of the bus bar terminal 62 may be coupled with one side of the fourth terminal 522 to receive any one of three-phase (U, V, and W) power.

As shown in FIG. 25 , the plate 525 may be disposed on the lower side of the bracket body 521 to cross the cavity 523 . At this time, the plate 525 may be formed in a plate shape. Accordingly, the plate 525 contacts the lower surface 511a of the power module body 511 to bring the power module 511 into close contact with the controller cover 400 .

The hooks 526 may be disposed on the bracket body 521 spaced apart from each other. At this time, the hook 526 may be formed to protrude upward from the bracket body 521 .

When the power module 510 is placed in the cavity 523, the hook 526 fixes the power module body 511 to the bracket body 521. At this time, a second groove 415 may be formed on the lower surface 414 of the controller cover body 410, and the end of the hook 426 may be disposed in the second groove 415 of the controller cover 400. there is. Accordingly, when the controller cover 400 and the power module unit 500 are coupled, interference by the hook 526 is prevented.

As shown in FIG. 27 , the hook 526 may be spaced apart from an imaginary line L passing through the center of the power module body 511 at a predetermined interval d. Accordingly, when the controller cover 400 and the power module unit 500 are coupled, the second groove 415 and the hook 526 are coupled so that the power module unit 500 can be assembled at a preset position.

As shown in FIG. 30 , the fourth protrusion 527 may protrude into the cavity 523 . Also, the fourth protrusion 527 is coupled to the fourth groove 514 of the power module 510 . Accordingly, when the power module 510 and the bracket 420 are coupled, the fourth protrusion 527 is disposed in the fourth groove 514, so that the fourth protrusion 527 guides the coupling of the power module 510. can do. Here, the fourth protrusion 527 may be referred to as a guide protrusion.

The fourth protrusion 528 may be formed to protrude downward from the bracket body 521 . In this case, the fourth protrusion 528 may be disposed adjacent to the first pin 512 . Here, adjacency means being in contact or spaced apart at a predetermined interval. Here, the fourth protrusion 528 may be referred to as a protection unit.

Thus, the fourth protrusion 528 may protect the first pin 512 . For example, when the first fin 512 is coupled to the substrate 600, the fourth protrusion 528 supports a portion of the first fin 512, thereby preventing or minimizing the bending of the first fin 512. can do.

As shown in FIG. 30 , the fourth protrusion 528 may include a 4-1 protrusion 528a and a plurality of 4-2 protrusions 528b.

The 4-1 protrusion 528a may be formed in a plate shape. Also, the 4-2 protrusion 528b may protrude toward the first pin 512 from one surface of the 4-1 protrusion 528a. Accordingly, the first pin 512 may be disposed between the 4-2 protrusions 528b.

As shown in FIG. 28, for coupling the end of the first pin 512 and the substrate 600, the protruding height H1 of the fourth protrusion 528 relative to the lower surface 414 of the controller cover 400 ) is smaller than the protrusion height H2 of the first pin 512 . That is, the protrusion height H2 of the first pin 512 is greater than the protrusion height H1 of the fourth protrusion 528 . Here, the protruding height may be referred to as a protruding length.

The fourth terminal 522 electrically connects the first terminal pin 513a and the bus bar terminal 62 of the motor 3.

Referring to FIGS. 25 and 27 , one end of the fourth terminal 522 is bent downward and exposed, and the other end may be disposed inside the fourth boss 524 .

31 is a diagram showing a fourth terminal of the power module unit according to the first embodiment.

Referring to FIG. 31, the fourth terminal 522 includes a fourth body 522a disposed horizontally, a fourth frame 522b formed to protrude downward from one end of the fourth body 522a, and a fourth body. After being bent downward from the other end of 522a, a fourth end 522c bent in a horizontal direction may be included. Here, a sixth hole 522d may be formed in the fourth end portion 522c. At this time, the fourth end 522c is disposed to be exposed to the inside of the fourth boss 524 . Here, the sixth hole 522d may be called an insertion hole or a hole.

The fourth frame 522b may be disposed to contact the first terminal pin 513a. In this case, contact force between the fourth frame 522b and the first terminal pin 513a may be improved through a fusing process.

An end of the bus bar terminal 62 may be coupled to the sixth hole 522d. In this case, two sixth holes 522d may be formed to improve bonding force and contact force with the end of the bus bar terminal 62 .

Meanwhile, a heat transfer member (not shown) may be further disposed between the power module 510 of the power module unit 500 and the controller cover 400 . Accordingly, heat generated by the power module 410 is conducted to the controller cover 400 through the heat transfer member. Here, a thermal pad, thermal grease, or the like may be used as the heat transfer member.

32 is a view showing a substrate of a motor assembly according to an embodiment.

The substrate 600 may prevent reverse connection of power. Here, the reverse connection means that the positive and negative poles of the power source are applied differently from those previously set, and as a result, the motor assembly 1 may be damaged. Therefore, the substrate 600 may be prevented from being damaged by using the MOSFET even if the positive and negative electrodes of the power source are applied differently from those previously set.

That is, the controller 2 receives power from an external connector coupled to the first boss 111, removes noise from the CM filter unit 200 and the DM filter unit 300, and transfers it to the substrate 600. In addition, power for which reverse connection is prevented in the substrate 600 is transferred to the DM filter unit 300 and then supplied to the power module unit 500 and the substrate 600 .

In addition, the board 600 may transmit and receive signals with the external connector through the first connector 700 and the second connector 800 . In addition, the substrate 600 may transmit and receive signals to and from the power module unit 500 .

Referring to FIG. 32 , a substrate 600 may include a substrate body 610 on which circuit wiring is disposed, a plurality of seventh holes 620 , a MOSFET 630 and a sensor 640 . Here, the substrate body 610 may be referred to as a seventh body. Also, the seventh hole 620 may be called a through hole.

A plurality of seventh holes 620 may be formed in the substrate body 610 . In the seventh hole 620, the end of the third frame 322, the end of the 3-1 frame 332, the end of the 3-2-2 frame 342b, and the 3-3 frame 352 An end of the first pin 512 and an end of the third protrusion 515 may be disposed. Also, each end portion may be soldered and fixed to the substrate body 610 .

The MOSFET 630 may be disposed on top of the substrate body 610 .

In the MOSFET 630 , noise is removed by the CM filter unit 200 and the DM filter unit 300 to prevent reverse connection of power supplied to the substrate body 610 .

The sensor 640 may be disposed on top of the substrate body 610 .

The sensor 640 detects whether a signal is properly transmitted to the motor 3 through the third protrusion 515 .

33 is a view showing the first connector of the motor assembly according to the embodiment.

The first connector 700 electrically connects an external connector coupled to the second boss 112 and the substrate 600 . At this time, one side of the first connector 700 is coupled to the board 600 .

Referring to FIG. 33 , the first connector 700 may include a first connector body 710 and a plurality of first connector pins 720 . Here, the first connector body 710 may be formed of a synthetic resin material, and the first connector pin 720 may be formed of a metal material. Also, the first connector body 710 may be referred to as an eighth body. Also, the first connector pin 720 may be called a second pin.

One side of the first connector pin 720 is connected to an external connector coupled to the second boss 112, and the other side is electrically connected to the substrate 600.

34 is a view showing a second connector of a motor assembly according to an embodiment,

The second connector 800 electrically connects an external connector coupled to the third boss 113 and the board 600 . At this time, one side of the second connector 800 is coupled to the board 600 .

Referring to FIG. 33 , the second connector 800 may include a second connector body 810 and a plurality of second connector pins 820 . Here, the second connector body 810 may be formed of a synthetic resin material, and the second connector pin 820 may be formed of a metal material. Also, the second connector body 810 may be referred to as a ninth body. Also, the second connector pin 820 may be referred to as a third pin.

One side of the second connector pin 820 is connected to an external connector coupled to the third boss 113, and the other side is electrically connected to the substrate 600.

1 to 3, the motor 3 according to the embodiment includes a motor housing 10 having an opening formed on one side, a motor cover 20 covering the opening of the motor housing 10, and an inner side of the housing 10. It may include a stator 30 disposed on the stator 30, a rotor 40 disposed rotatably on the stator 30, a rotary shaft 50 rotating together with the rotor 40, and a bus bar 60. At this time, a bearing 70 may be disposed on an outer circumferential surface of the rotation shaft 50 for rotation of the rotation shaft 50 .

Here, the motor housing 10 and the motor cover 20 may form the outer shape of the motor 3 . In addition, an accommodation space may be formed by combining the motor housing 10 and the motor cover 20 . Accordingly, as shown in FIG. 3 , the stator 30 , the rotor 40 , the rotating shaft 50 and the bus bar 60 may be disposed in the accommodation space.

The motor housing 10 may be formed in a cylindrical shape to form the accommodation space. Also, an inner circumferential surface of the motor housing 10 may be coupled with an outer circumferential surface of the third protrusion 420 .

At this time, the motor housing 10 may be formed of a metal material. Accordingly, heat transmitted through the motor cover 400 is discharged to the outside through the motor housing 10 . Also, since the motor housing 10 comes into contact with the motor cover 400, it can perform a grounding function.

The motor cover 20 is disposed in the upper side opening of the motor housing 10 . At this time, a bearing 70 may be disposed inside the motor cover 20 .

The stator 30 may be disposed inside the motor housing 10 . And, the stator 30 causes an electrical interaction with the rotor 40.

Referring to FIG. 3 , the stator 30 may include a stator core 31 and a coil 33 wound around the stator core 31 . Also, the stator 30 may further include an insulator 32 disposed between the stator core 31 and the coil 33 . The insulator 32 insulates the stator core 31 and the coil 33.

The stator core 31 may be formed by stacking plate-shaped plates to a predetermined height.

The rotor 40 may be disposed inside the stator 30 and may be disposed on an outer circumferential surface of the rotating shaft 50 . Here, the rotor 40 may be rotatably disposed on the stator 30 .

The rotor 40 may be formed by stacking a plurality of disk-shaped core plates. The magnets disposed on the rotor 40 are disposed facing the stator 30, and each magnet may be formed of an IPM type inserted into and coupled to the rotor 40 through a hole formed inside the rotor 40.

The rotor 40 may be configured in a type in which a magnet is disposed on the outer circumferential surface of the rotor core.

Therefore, the rotor 40 rotates due to the electrical interaction between the coil 33 and the magnet. And, as the rotor 40 rotates, the rotating shaft 50 rotates to generate a driving force.

The rotating shaft 50 may be disposed through the central portion of the rotor 40 . When a driving current is applied to the stator 30, the rotor 40 rotates due to electromagnetic interaction between the stator 30 and the rotor 40, and thus the rotating shaft 50 interlocks with the rotation of the rotor 40. to rotate

The bus bar 60 is disposed above the stator 30.

The bus bar 60 may include a bus bar body 61 and a bus bar terminal 62 inside the bus bar body 61 . Here, the bus bar body 61 may be a molded product formed through injection molding.

The bus bar terminal 62 may be a phase terminal connected to power of phases U, V, and W.

Connection ends of the bus bar terminals 62 are exposed from the bus bar body 61. Accordingly, the connection end of the bus bar terminal 62 may be connected to the coil 33 as shown in FIG. 3 .

35 is a view showing a bus bar terminal of a motor assembly according to an embodiment.

Referring to FIG. 35 , the bus bar terminal 62 may include a bus bar terminal body 62a and a fifth frame 62b protruding upward from the bus bar terminal body 62a. Here, the fifth frame 62b may be referred to as a coupling end.

The fifth frame 62b may pass through the motor cover 20 and protrude toward the top of the motor cover 20 .

An end of the fifth frame 62b is guided by the fourth boss 524 and coupled to one side of the fourth terminal 522 disposed inside the fourth boss 524 . In this case, two protrusions may be formed spaced apart from each other at an end of the fifth frame 62b, and the protrusions may be coupled to the sixth hole 522d of the fourth terminal 522.

Meanwhile, a power module unit 500a according to the second embodiment may be disposed in the motor 1 according to the embodiment instead of the power module unit 500 according to the first embodiment.

36 is an exploded perspective view illustrating a motor according to an embodiment in which a power module unit 500a according to the second embodiment is disposed.

Referring to FIGS. 1 and 36 , a motor 1 according to an embodiment may include a controller 2 and a motor 3 . The controller 2 includes a controller housing 100, a CM filter unit 200, a DM filter unit 300, a controller cover 400, a power module unit 500a according to the second embodiment, and a substrate 600. , the first connector 700 and the second connector 800 may be included.

Hereinafter, in describing the motor 1 according to the embodiment in which the power module unit 500a according to the second embodiment is disposed, the motor 1 in which the power module unit 500 according to the first embodiment is disposed The same components described in are denoted by the same reference numerals, the controller housing 100, the CM filter unit 200, the DM filter unit 300, the controller cover 400, the substrate 600, the first connector ( 700) and a detailed description of the second connector 800 will be omitted.

Power for which reverse connection is prevented in the board 600 is transferred to the DM filter unit 300 and then supplied to the power module unit 500a.

And, the power module unit 500a transmits a signal capable of controlling the motor 3. At this time, the power module unit 500a is in close contact with the lower surface 414 of the controller cover 400 .

37 is a perspective view showing a power module part according to a second embodiment of a motor assembly according to an embodiment, and FIG. 38 is a bottom perspective view showing a power module part according to a second embodiment of a motor assembly according to an embodiment, and FIG. 39 is It is a plan view showing the power module part according to the second embodiment of the motor assembly according to the embodiment.

37 to 39 , the power module unit 500a may include a power module 510a and a mold unit 530 surrounding the power module 510a. At this time, the power module 510a may be disposed in the mold unit 530 through an injection method. Here, the mold unit 530 may be formed of a synthetic resin material. Since the power module unit 500a is formed according to the injection method, it is possible to reduce material cost and mold cost, thereby reducing production cost.

The power module 510a transmits a signal capable of controlling the motor 3. Here, an automotive power module (APM) may be used as the power module 510a.

40 is a diagram showing a power module of the power module unit according to the second embodiment.

Referring to FIG. 40 , the power module 510a may include a power module body 511a, a plurality of power module pins 512 disposed to protrude downward from one side of the power module body 511, and a terminal portion.

The terminal unit includes two first power module terminals 513b disposed so that one area protrudes downward from the other side of the power module body 511a and three second power module terminals (one side of which is connected to the power module body 511a) 516) may be included.

Here, the power module pin 512 is the same component as the first pin 512 of the power module unit 500 according to the first embodiment.

In addition, the first power module terminal 513b is the same component as the second terminal pin 513b of the power module unit 500 according to the first embodiment. And, the second power module terminal 516 is a component obtained by integrally transforming the first terminal pin 513a and the fourth terminal 522 of the power module unit 500 according to the first embodiment.

One side of the power module body 511a is placed in close contact with the lower surface 414 of the controller cover 400. As shown in FIG. 37 , the power module body 511a may be formed in a concave-convex shape with a partial area protruding. That is, the power module body 511a may include the power module body 511 according to the first embodiment and a protrusion area A protruding from one side of the power module body 511 according to the first embodiment.

Therefore, when compared with the power module body 511 of the power module unit 500 according to the first embodiment, the contact area of the power module body 511a is in contact with the controller cover 400 by the protruding area A. This increases and the heat dissipation performance is improved. In addition, since the size of the power module main body 511a can be enlarged, the degree of freedom in design increases.

The power module pin 512 and the first power module terminal 513b may face each other and be spaced apart from each other. And, the end of the power module pin 512 is coupled to the board 600 to receive a signal from the board 600. At this time, the power module pins 512 may be fixed to the substrate 600 through soldering.

One side of the first power module terminal 513b may be electrically connected to the controller housing body 510, and the other side may be bent downward.

As shown in FIG. 40 , one side of the second power module terminal 516 may be connected to the protruding area A of the power module body 511a, and the other side may protrude outward from the mold part 530. In this case, the power module pin 512 and one area of the first power module terminal 513b protruding downward may face each other and be spaced apart from each other.

Each of the two first power module terminals 513b is the 3-2-1 frame 342a of the 3-2 terminal 340 and the 3-3-3 frame 352c of the 3-3 terminal 350. ) and is electrically connected to receive power. In this case, the first power module terminal 513b may be disposed with the protruding area A of the power module body 511 interposed therebetween.

The second power module terminal 516 allows power to be supplied to the motor 3 . Here, the second power module terminal 516 may be formed of a metal material.

One end of the second power module terminal 516 may be connected to one side of the power module body 511a, and the other end may be disposed inside the boss part 531. As shown in FIG. 40 , one end of the second power module terminal 516 may be disposed in the protrusion area A of the power module body 511a.

Referring to FIG. 40, the second power module terminal 516 is disposed horizontally and includes a fourth body 516a and a fourth body having one end connected to the protrusion area A of the power module body 511a. After being bent downward from the other end of 516a, a fourth end 516c bent in a horizontal direction may be included. Here, a sixth hole 516d may be formed in the fourth end portion 516c. In this case, the fourth end portion 516c having the sixth hole 516d is exposed to the inside of the boss portion 531 . Here, the fourth body 516a may be referred to as a power module terminal body. Also, the sixth hole 516d may be called an insertion hole or a hole.

An end of the bus bar terminal 62 may be coupled to the sixth hole 516d. At this time, two sixth holes 516d may be formed to improve bonding force and contact force with the end of the bus bar terminal 62 .

The mold part 530 may be disposed to surround one area of the power module 510a. Here, the mold part 530 may be divided into a first region surrounding the power module body 511 and a second region surrounding the protruding region A.

A boss portion 531 and a groove 532 may be formed in the mold portion 530 . Here, the boss portion 531 may be disposed in the second area. Also, the groove 532 may be disposed in the first region.

Referring to FIG. 39 , the width W3 of one side of the mold portion 530 in which the boss portion 531 is formed is smaller than the width W4 of the other side facing each other. For example, the width W3 of the second area is smaller than the width W4 of the first area. Here, width W3 : width W4 = 16:37.

Each of the three boss parts 531 may be formed to protrude downward from one side of the mold part 530 . At this time, the boss portion 531 protrudes toward the substrate 600 and, as shown in FIG. 38 , is branched into three parts from the mold portion 530 . Here, the boss portion 531 may be disposed in the second area adjacent to the protruding area A.

A space may be formed inside each of the boss portions 531 , and a fourth end portion 516c of the second power module terminal 516 may be disposed inside the boss portion 531 . At this time, the space may be formed in a shape penetrating from the lower part to the upper part of the boss part 531 .

And, each of the boss parts 531 guides the coupling of the motor 3 with one area of the bus bar terminal 62. Accordingly, one area of the bus bar terminal 62 is coupled to the fourth end 516c of the second power module terminal 516 to receive any one of three-phase (U, V, W) power. there is.

Meanwhile, a protrusion 531a may be further formed at a lower end of each boss 531 .

The protrusion 531a protrudes downward from the lower end of the boss 531 . Accordingly, the space of the boss portion 531 extends downward by the protrusion portion 531a. As shown in FIG. 38 , the protrusion 531a may be formed in a quadrangular shape on a plane.

Two grooves 532 may be formed on both sides of the power module body 511 . Further, the power module unit 500a is tightly fixed to the lower surface 414 of the controller cover 400 by a fastening member (not shown) such as a bolt or a screw penetrating the groove 532 .

Although the above has been described with reference to the embodiments of the present invention, those skilled in the art can variously modify and modify the present invention within the scope not departing from the spirit and scope of the present invention described in the claims below. You will understand that it can be changed. And, it should be construed that the differences related to these modifications and changes are included in the scope of the present invention, which is defined in the appended claims.

1: motor assembly
10: motor housing 20: motor cover
60: bus bar
100: controller housing 200: CM filter unit
300: DM filter unit 400: motor cover
500, 500a: power module unit
600: substrate 630: MOSFET
700: first connector 800: second connector

Claims (17)

Board;
a controller housing disposed on the substrate;
a CM filter unit disposed between the substrate and the controller housing;
a DM filter unit disposed under the CM filter unit;
a controller cover disposed between the substrate and the DM filter unit;
a power module unit disposed between the substrate and the controller cover; and
Including a connector coupled to the substrate,
The power module part
power module; and
It includes a mold part surrounding the power module,
The mold part includes a boss protruding from one side,
The power module
power module body;
a terminal pin coupled to one side of the power module body;
a terminal unit coupled to the other side of the power module body; and
The power module body includes a protruding area protruding from one side,
The terminal unit includes two first power module terminals protruding from the other side of the power module body to the outside of the mold unit; And three second power module terminals, one side of which is connected to the other side of the power module body,
The power module body and the protruding area are in close contact with the controller cover formed of a metal material,
The protruding area is disposed between the two first power module terminals. According to claim 1,
An end of the terminal pin is a controller for a motor coupled to the substrate. delete According to claim 1,
The second power module terminal is
a body having one end connected to the power module body;
an end bent from the other end of the body and disposed inside the boss; and
A controller for a motor comprising a hole formed at the end. According to claim 1,
The controller for a motor branching from the mold part into three boss parts. According to claim 5,
The boss portion protrudes toward the substrate,
The other side of the second power module terminal is a controller for a motor disposed to be exposed to the inside of the boss part. According to claim 6,
A space is formed inside the boss part,
The space is a controller for a motor formed in a shape penetrating from the bottom to the top. According to claim 6,
A controller for a motor in which a protrusion protruding downward is further formed at the lower end of the boss portion. According to claim 5,
A controller for a motor in which a width of one side of the mold portion in which the boss portion is formed is smaller than a width of the other side of the mold portion disposed to face each other. According to claim 1,
A controller for a motor in which one side of the first power module terminal protrudes to the outside of the mold part is disposed to protrude downward. delete According to claim 1,
The other side of the second power module terminal is connected to the protruding area of the motor controller. delete a controller for the motor, and
includes a motor;
The controller for the motor
Board;
a controller housing disposed on the substrate;
a CM filter unit disposed between the substrate and the controller housing;
a DM filter unit disposed under the CM filter unit;
a controller cover disposed between the substrate and the DM filter unit;
a power module unit disposed between the substrate and the controller cover; and
Including a connector coupled to the substrate,
The power module part
power module; and
It includes a mold part surrounding the power module,
The mold part includes a boss protruding from one side,
The power module
power module body;
a terminal pin coupled to one side of the power module body;
a terminal unit coupled to the other side of the power module body; and
The power module body includes a protruding area protruding from one side,
The terminal unit includes two first power module terminals protruding from the other side of the power module body to the outside of the mold unit; And three second power module terminals, one side of which is connected to the other side of the power module body,
The power module body and the protruding area are in close contact with the controller cover formed of a metal material,
The motor assembly of claim 1 , wherein the protruding area is disposed between the two first power module terminals. According to claim 14,
the motor
axis of rotation;
a rotor disposed outside the rotating shaft;
a stator disposed outside the rotor;
a bus bar disposed above the stator;
a motor housing accommodating the rotor, the stator, and the bus bar; and
And a motor cover disposed in the opening of the motor housing,
The bus bar
bus bar body; and
Including bus bar terminals,
One side of the bus bar terminal is coupled to the hole of the second power module terminal. According to claim 15,
The connector unit includes a first connector and a second connector,
Each of the first connector and the second connector penetrates the controller cover. According to claim 16,
One side of the first connector is coupled to the board and the other side is disposed inside any one of three bosses formed in the controller housing,
One side of the second connector is coupled to the board and the other side is disposed inside the other one of the three bosses formed in the controller housing.

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