Electronic control unit and electric power steering system

Abstract

The invention relates to an electronic control unit for an electric power assisted steering system comprising a housing and an electric motor, the electronic control unit being configured to be arranged within the housing and electrically connected to the electric motor, wherein the electronic control unit comprises a first power supply board having a first electric motor connector for electrically connecting to the electric motor, a second power supply board having a second electric motor connector for electrically connecting to the electric motor, and a connector board of the electronic control unit is electrically connected to the first power supply board by at least one first power supply connector and to the second power supply board by at least one second power supply connector via at least one plug connector of the connector board, wherein the at least one first power supply connector is shorter than the at least one second power supply connector. The invention further relates to an electric power assisted steering system.

Description

Technical Field

[0001] This invention relates to an electronic control unit for an electric power steering system and an electric power steering system. Background Technology

[0002] In an electric power steering system, an electronic control unit can be connected to an electric motor to supply power to the motor from a power source (such as a battery). The electric power steering system assists the driver in maneuvering a vehicle, typically a car.

[0003] An electric power steering system may further include a torque sensor, a steering shaft, a control unit (typically a steering wheel), and a power source. The typical arrangement and operation of an electric power steering system in a car will be described below.

[0004] A torque sensor can be mounted on the steering shaft. When the steering shaft is rotated via an operating mechanism, the torque sensor detects the torque applied to the steering shaft by the operating mechanism. After detecting the torque, the torque signal is output from the torque sensor to the electronic control unit (ECU). The ECU then drives the electric motor based on at least the torque signal. Optionally, in addition to the torque signal used to control the drive of the electric motor, the control device may also include other data, such as vehicle speed.

[0005] The electronic control unit drives the electric motor by supplying drive current from a power source (such as the car's battery). The driving force generated from the electric motor is then transmitted to the wheels directly or through a gearbox, depending on the car's construction. Thus, electric power steering changes the steering angle of the wheels by utilizing the electric motor to amplify the torque of the steering shaft. This allows the driver to operate the steering mechanism with less force.

[0006] The electronic control unit includes a power board that is electrically connected to the electric motor. Power to the electric motor is transmitted through this power board. Therefore, this power board generates heat during the operation of the electronic control unit. To prevent overheating and damage to the electronic control unit, a heat sink can be installed inside the electronic control unit and arranged to make thermal contact with the housing of the electric power steering system or the electric motor.

[0007] DE 10 2016 212 862 A1 describes a power unit for an electric steering system. The power unit includes a motor housing for a motor, a radiator, and control electronics for the motor connected to the radiator. Summary of the Invention

[0008] The object of the present invention is to improve the electronic control unit and electric power steering system known in the art for electric power steering systems, and in particular to provide an electronic control unit and electric power steering system for electric power steering systems with improved assembly characteristics, particularly a compact, low-cost and easy-to-assemble design.

[0009] The features and details associated with the electronic control unit of the present invention apply to electric power steering systems and vice versa, so disclosures relating to various aspects of the present invention are cross-referenced, or may be cross-referenced.

[0010] According to a first aspect of the invention, the problem is solved by an electronic control unit for an electric power steering system, the electric power steering system including a housing and an electric motor, the electronic control unit being configured to be disposed within the housing and electrically connected to the electric motor, wherein the electronic control unit includes: a first power board having a first electric motor connector for electrical connection to the electric motor; a second power board having a second electric motor connector for electrical connection to the electric motor, and wherein the connector board of the electronic control unit is electrically connected to the first power board via at least one plug connector of the connector board, via at least one first power connector, and via at least one second power connector to the second power board, wherein the at least one first power connector is shorter than the at least one second power connector.

[0011] By providing different lengths for the first and second power connectors, improved assembly characteristics of the electronic control unit are achieved, particularly a compact, low-cost, and easy-to-assemble design. That is, the first and second power boards can be positioned at different distances from the connector board. Furthermore, the first and second power boards can be arranged parallel to each other.

[0012] In particular, the first power connector may have a first length corresponding to the distance between the first power board and the connector board, and the second power connector may have a second length corresponding to the distance between the second power board and the connector board, wherein the first length is less than the second length.

[0013] The first and second power boards can be configured as printed circuit boards. These power boards may include electronic components, such as coils and capacitors, to enable the power boards to transmit power from a power source to the electric motor.

[0014] The electric motor can be housed within a housing. The housing can be, in particular, an electric motor housing, i.e., the casing of the electric motor. The housing can, in particular, have a tubular shape. The housing can, in particular, have a circular or elliptical cross-section. Furthermore, the housing can be made of a thermally conductive material. The thermally conductive material can, in particular, be or include metals such as aluminum, magnesium, copper, or similar materials.

[0015] In particular, two power boards can be independently connected to a connector board, thereby connecting to a power source. The connector board can be made of plastic, for example. The connector board can be formed as a cover for sealing the end of the housing. The connector board can be provided with a seal for sealing the interior of the housing relative to the exterior. This seal can be made of silicone rubber. The connector board can include one, two, three, or more connectors, particularly plug connectors. Electrical contacts can be provided at or within the plug connectors. The electrical contacts can be made of, for example, a copper alloy to provide good conductivity. One or more plug connectors can be provided for contacting the control board of the transport equipment with the logic board. Thus, torque sensors, other sensors, and / or other electronic control units can be connected to the logic board. The plug connectors can be connected to the power board via power connectors.

[0016] It is possible that the connector board is connected to the first power board via two first power connectors and to the second power board via two second power connectors, wherein the two first power connectors are shorter than the two second power connectors.

[0017] Furthermore, it is possible that the at least one first power connector and / or the at least one second power connector are configured as a metal strip. In particular, the metal strip can be configured as a metal plate. Aluminum, copper, the aforementioned alloys, or other metals with high conductivity can be used for the metal strip. The at least one first power connector and the at least one second power connector can have a flat and / or rectangular shape. The metal strip can be bent along its length to be positioned within the electronic control unit according to the determined geometry of other components of the electronic control unit, such as power boards and logic boards.

[0018] It is also possible that the length of the at least one second power connector is at least 120% of the length of the first power connector, particularly at least 150%, and further particularly at least 200%. Therefore, a large heatsink (i.e., a heatsink with a large thickness) can be arranged between the two power boards to provide good heat dissipation characteristics.

[0019] It is possible that each of the first and second power boards is supplied with three-phase power to provide three-phase power to the electric motor. Therefore, both power boards can independently provide three-phase power to the electric motor. Furthermore, it is possible that the first and second power boards are arranged to provide three-phase power to the electric motor in the event of a failure of the other power board. For this purpose, the logic board of the electronic control unit can be arranged to detect a failure of one of the two power boards and instruct the operating power board to drive the electric motor. Additionally, it is possible that the first and second power boards are arranged as redundant power boards to provide six-phase power to the electric motor. Therefore, the electric motor can be a six-phase electric motor. Thus, better and more reliable power transmission to the electric motor can be achieved. In particular, if one of the two power boards fails, the other power board can still operate to provide power to the electric motor. Therefore, the electric motor can be driven independently by the drive current provided by either or both power boards. Therefore, it can be ensured that the electronic control unit can safely power the electric motor even if one of the two power boards fails. This provides a redundant design for the electronic control unit and electric power steering system, making them less prone to failure.

[0020] Furthermore, it is possible for the logic board to be sandwiched between the first power board and the connector board. This logic board can be supplied specifically as a printed circuit board. The logic board does not necessarily need to be connected to the heatsink of the electronic control unit. In particular, the logic board can be left unconnected to the heatsink. Since the logic board generates less heat during the operation of the electronic control unit than the two power boards, it is preferable to connect the two power boards, which generate more heat during the operation of the electronic control unit, to the heatsink.

[0021] Therefore, it is possible for the logic board to be logically connected to at least one of the at least one plug connectors of the connector board via at least one signal connector. Thus, the logical connection between the connector board and the logic board is separate from its power connection to the power board.

[0022] Alternatively, the first power board may include at least one first power board recess, through which the at least one second power connector extends to the second power board. Therefore, the first power connector can be easily guided through the first power board and to the second power board.

[0023] Alternatively, the electronic control unit may include a heat sink sandwiched between a first power board and a second power board. The first power board may be positioned on one side of the heat sink, and the second power board on the other. The first and second power boards can be directly connected to the heat sink using their circuit boards and electronic components. A thermal interface material may be provided between the first power board and the heat sink, and between the second power board and the heat sink, to thermally connect the respective components to each other for better thermal conductivity.

[0024] Both power boards can be connected to the radiator. Specifically, both power boards can be mounted on the radiator. The two power boards can be surrounded by the radiator's edge. The radiator's edge can include grooves arranged to press the housing into the grooves, thereby securing the radiator and housing together at least and potentially thermally connecting them. When the housing is pressed into the radiator's groove, a particularly tight fit of the radiator within the housing is achieved, improving thermal conductivity from the radiator to the housing. Furthermore, the overall contact surface between the radiator and the housing is further increased, further improving overall thermal conductivity from the radiator to the housing. Additionally, providing a radiator with grooves during radiator manufacturing can be done at a relatively low cost, and pressing the housing into the groove is a relatively simple, quick, and cost-effective way to secure the radiator, particularly within the entire electronic control unit housing with an electric power steering system. Pressing can be performed by squeezing the outer side of the housing into the groove. This plastically deforms the housing and brings it into contact with the radiator at the groove. For example, the groove can have a rectangular, U-shaped, or V-shaped shape. Furthermore, more than one groove may be provided for pressing it against the housing in the radiator. For example, the radiator edge may include at least two grooves for pressing the housing into said at least two grooves.

[0025] The heat sink can be configured as a at least partially circular hot plate. Specifically, the heat sink can be at least a semi-circular or fully circular hot plate. The heat sink edge can have a circle that surrounds or encloses the hot plate. The heat sink can be a flat plate, i.e., its thickness is less than its diameter or radius. The heat sink can include several thermally conductive surfaces arranged to contact the electronic components of the power board. A thermal interface material can be provided between the electronic components and the thermally conductive surfaces. Therefore, heat generated by the electronic components can be conducted to the heat sink very efficiently. The several thermally conductive surfaces can be arranged at different heights along the thickness of the heat sink to accommodate electronic components of different heights. Therefore, the at least one power board can maintain design freedom regarding its specific electronic components, such as their size and geometry, while still enabling the power board to have high thermal conductivity with respect to the heat sink. In other words, the heat sink can be adapted in its form and geometry to the at least one power board, rather than the other way around.

[0026] Alternatively, the heatsink may include heatsink through-holes, and the first power board may be secured to the heatsink by bolts passing through the heatsink through-holes and fixed in an arched portion extending from the connector board. This makes the connection between the power board and the heatsink, and further to the connector board, simple, reliable, and removable.

[0027] Alternatively or additionally, the heatsink may include heatsink holes, and the second power board may be secured to the heatsink by bolts fixed in the heatsink holes. Thus, a simple, reliable, and detachable connection is provided between the second power board and the heatsink.

[0028] In particular, the first power board can be connected via through-holes in the heatsink and the arched portion in the connector board, and the second power board can be connected via holes in the heatsink. This provides exceptionally good maintainability, as the second power board can be replaced without removing the first power board from the heatsink, and further enhances the reliability of the secure connection.

[0029] Alternatively, the heat sink may include a heat sink recess for the at least one second power connector, which extends from the connector board through the heat sink recess inside the heat sink to the second power board. The at least one second power connector can be used to transfer current from the connector board, which is connectable to a power source, to the second power board. The heat sink recess allows for a simple and economical design of both the heat sink and the at least one second power connector. The heat sink recess can be designed as a flat groove.

[0030] Alternatively, the heat sink may include a heat sink cutout, specifically extending from the edge of the heat sink into its interior, through which a second logic connector extends from the logic board of the electronic control unit to a second power board. The heat sink cutout may have a partially circular and / or partially flat shape. The heat sink cutout allows for a simple and economical design for both the heat sink and the second logic connector.

[0031] Therefore, it is possible for the first electric motor connector from the second power board to extend through a radiator cutout to connect to the electric motor of the electric power steering system. This reduces the number of cutouts or recesses, allowing for a more compact design of the electronic control unit. Drive current from the first power board can be transmitted to the electric motor via the radiator through the first electric motor connector.

[0032] Furthermore, it is possible that the radiator includes a radiator protrusion extending beyond the first and second power boards and arranged to rest on the inner edge of the housing within the electric power steering system. The radiator protrusion allows for easy detection of the end position of the electronic control unit (ECU) within the housing when it is installed. The end position is reached when the protrusion rests on the inner edge of the housing and the ECU cannot be pushed further into the housing without excessive force bends or damages the protrusion. Therefore, a defined position is provided where the housing is pressed into the groove, and this pressing can be performed at this defined position each time the radiator and housing are connected, which facilitates manufacturing.

[0033] According to a second aspect of the invention, the problems raised in the description herein are solved by an electric power steering system comprising an electronic control unit according to a first aspect of the invention, wherein the electric motor of the electric power steering system is electrically connected to a first power board via a first electric motor connector and to a second power board via a second electric motor connector.

[0034] When the radiator includes protrusions extending beyond the at least one power board, these protrusions can rest on the inner edge of the housing of the electric power steering system. Therefore, the precise location of the electronic control unit within the housing and its stable connection thereto are achieved.

[0035] The electric power steering system may further include a torque sensor, a steering shaft, control elements (particularly a steering wheel), and a power source. The electric power steering system may further have the arrangements described in the introductory section of this specification and is configured for operation in a vehicle.

[0036] Further advantages, features, and details of the invention are set forth in the following description, wherein embodiments of the invention are described in detail with reference to the following figures. Therefore, the features in the claims, as well as the individual forms or any combinations thereof mentioned in the specification, can be essential to the invention. Attached Figure Description

[0037] The figure shows:

[0038] Figure 1 : An exploded view of the bottom perspective of an embodiment of an electronic control unit according to the first aspect of the present invention.

[0039] Figure 2 : Figure 1 Exploded view of the top three-dimensional structure of the electronic control unit.

[0040] Figure 3 : Figure 1 and Figure 2 A detailed side perspective view of the two power boards and logic board of the electronic control unit is shown.

[0041] Figure 4 Detailed side perspective view of the assembled logic board with connector board.

[0042] Figure 5 : A detailed side perspective view showing the assembled logic board, connector board, and first power board.

[0043] Figure 6 : Figure 1 and Figure 2 A detailed side perspective view of the heat sink of the electronic control unit is shown.

[0044] Figure 7 : Figure 6 Radiator components and Figure 5 A detailed side perspective view of the assembled logic board, connector board, and first power board assembly is shown.

[0045] Figure 8 The assembled logic board and connector board, the assembled first power supply board, and Figure 6 A detailed side perspective view of the heat sink components is shown.

[0046] Figure 9 : Figure 1 and Figure 2 The electronic control unit 100 is shown in a side perspective view in its assembled state.

[0047] Figure 10 :assembly Figure 9 A side perspective view showing the process of an embodiment of the electronic control unit and the electric power steering system of the present invention; and

[0048] Figure 11 : pass through Figure 10 A cross-sectional view of an electric power steering system is shown, in which an electronic control unit is mounted. Detailed Implementation

[0049] Figure 1 An exploded view of the bottom perspective of an electronic control unit 100 according to an embodiment of the present invention is shown. According to this bottom perspective view, the bottom side of the components of the electronic control unit 100 is clearly shown.

[0050] Figure 2 It shows the relationship with Figure 1 The same electronic control unit 100, the difference is that... Figure 2This is a top-side perspective view. Based on this top-side perspective view, the top side of the components of the electronic control unit 100 is clearly shown.

[0051] from Figure 1 and Figure 2 As can be seen, the electronic control unit 100 includes two power boards 30 and 40, namely a first power board 30 and a second power board 40. Power boards 30 and 40 can also be referred to as power stages. These two power boards 30 and 40 are arranged to supply power to the electric power steering system 200 (see...). Figure 10 and 11 The electric motor (not shown) is supplied with drive current. For this purpose, the first power board 30 is connected to a first electric motor connector 80 that can be electrically connected to the electric motor. In addition, for this purpose, the second power board 40 is connected to a second electric motor connector 90 that can be electrically connected to the electric motor.

[0052] Furthermore, the electronic control unit 100 includes a connector board 10. The connector board 10 includes a plurality of (three in this particular embodiment) plug connectors 11.1, 11.2, and 11.3. In this particular embodiment, the first plug connector 11.1 and the second plug connector 11.2 have internal electrical contacts (not shown). The electrical contacts may be made of a copper alloy, for example, to allow good conductivity. These electrical contacts are arranged as first and second signal connectors 15.1 and 15.2. The signal connectors 15.1 and 15.2 extend from the plug connectors 11.1 and 11.2 on the top side of the connector board 10 to the bottom side of the connector board 10.

[0053] The electronic control unit 100 also includes a logic board 20. The logic board 20 is arranged to control the two power boards 30 and 40, or in other words, to control the operation of the electronic control unit 100, or further, to control the transmission of drive current to the electric motor. For this purpose, signal connectors 15.1 and 15.2 are connected to the logic board 20. Furthermore, the logic board 20 is connected to the first power board 30 via a first logic connector 70. Additionally, the logic board 20 is connected to the second power board 40 via a second logic connector 60.

[0054] Signal plugs (not shown) can be connected to plug connectors 11.1 and 11.2 to provide signals to logic board 20 from sensors (e.g., torque sensors) or other units (e.g., additional electronic control units from transportation equipment (not shown) (e.g., automobiles)). Through these signals, such as torque detected by the torque sensor or the speed of the transportation equipment, logic board 20 can control the drive current via two power boards 30 and 40.

[0055] The connector board 10 further includes a third plug connector 11.3. The third plug connector 11.3 internally includes further electrical contacts. These electrical contacts are configured as first power connectors 16.1, 16.2 and second power connectors 17.1, 17.2. The second power connectors 17.1, 17.2 are longer than the first power connectors 16.1, 16.2 so that they can be connected to their respective power boards 30, 40 at corresponding distances from the connector board 10. In this embodiment, the first power connectors 16.1, 16.2 and the second power connectors 17.1, 17.2 are configured as metal strips.

[0056] A power plug (not shown) can be connected to a third plug connector 11.3 to provide power to the first power connectors 16.1, 16.2 and the second power connectors 17.1, 17.2. The power plug can be connected to a power source, such as a battery (not shown) of a transport device. This power source is arranged as a three-phase power supply. Connector board 10 can also be referred to as a power and logic connector board because it provides power and logic or signal processing connections to the various boards 20, 30, 40 of the electronic control unit 100.

[0057] The first power connectors 16.1 and 16.2 are connected to the second power board 40, and the second power connectors 17.1 and 17.2 are connected to the first power board 30. Therefore, the first power board 30 is supplied with three-phase current, and the second power board 40 is supplied with three-phase current. Thus, the electronic control unit 100 is provided with six phases, and the electric motor can be configured as a six-phase electric motor. When one of the two power boards 30 and 40 fails due to an error, the other can ensure the safe and reliable operation of the electric motor by transmitting drive current to it. Therefore, an error in one of the power boards 30 or 40 can prevent unintended loss of steering function, as well as potential accidents and damage to the driver and passengers of the transport equipment.

[0058] from Figure 1 and Figure 2 It can be further understood that a heat sink 50 is arranged between the first power board 30 and the second power board 40. Therefore, the heat sink 50 is sandwiched between the two power boards 30 and 40. In this embodiment, the heat sink 50 is provided as die-cast aluminum. The heat sink 50 allows the heat generated in the two power boards 30 and 40 to be dissipated. For this purpose, the heat sink 50 is connected to the housing 210 of the electric power steering system 200, which will be described in detail later.

[0059] Additionally, connector plate 10 includes a vent 13 and a ventilation element (not shown) for closing the vent 13. When the electronic control unit 100 is inserted into housing 210 (this will also be described in detail below), the ventilation element provides pressure compensation between the interior of housing 210 and the environment. Furthermore, connector plate 10 includes a seal 12. In this particular embodiment, seal 12 is made of silicone rubber. When the electronic control unit 100 is inserted into housing 210, seal 12 seals the electronic control unit relative to the environment within housing 210.

[0060] Figure 3 The logic board 20, the first power board 30, and the second power board 40 are shown in more detail in exploded view. The logic board 20 includes first electronic components 21, wherein first electronic components 21.1, 21.2, and 21.3 are exemplarily named. Furthermore, the first power board 30 includes second electronic components 31, wherein second electronic components 31.1, 31.2, and 31.3 are exemplarily named. Furthermore, the second power board 40 includes third electronic components 41, wherein third electronic components 31.1, 31.2, and 31.3 are exemplarily named.

[0061] The first electronic component 21 may be a coil, a capacitor, at least one computing unit (e.g., a processor), and other electronic components, for performing computational operations based on received signals and logical communication between the logic board 20 and the two power boards 30, 40. The second and third electronic components 31, 41 may be coils, capacitors, and other electronic components, for enabling the respective power boards 30, 40 to transmit power from the power source to the electric motor, as will be explained further later.

[0062] The logic board 20, the first power board 30, and the second power board 40 are shown, for example, with their respective top and bottom sides facing each other, as if they were arranged within the electronic control unit 100. Thus, the largest of the second electronic components 31.1, 31.2, and 31.3 on the bottom side of the first power board 30 is shown as the largest of the third electronic components 41.1, 41.2, and 41.3 facing the second power board 40. These large electronic components 31 and 41 generate a large amount of heat, and with this arrangement, the heat sink 50 can receive the second and third electronic components 31 and 41, allowing for good thermal conductivity so that heat can be effectively dissipated from the two power boards 30 and 40 through the heat sink 50 and the housing 210.

[0063] Furthermore, the first power board 30 includes first power board recesses 32.1 and 32.2 for guiding the second power connectors 16.1 and 16.2 through them. Additionally, the first power board 30 includes power board through holes 33.1, 33.2, and 33.3 for guiding bolts 1 through them to secure the heat sink 50 to the connector board 10. These features will be explained in detail later.

[0064] Figure 4 The assembly of logic board 20 and connector board 10 is shown. First and second signal connectors 15.1 and 15.2 are connected to logic board 20. In particular, the first and second signal connectors 15.1 and 15.2 include a plurality of pins, which are connected to corresponding pin receiving holes in logic board 20.

[0065] The logic board 20 includes two logic connectors 60 and 70 connected thereto. The purpose of these two logic connectors is to enable communication and control of the two power boards 30 and 40 via the logic board 20. Therefore, each of the two logic connectors 60 and 70, namely the first logic connector 70 and the second logic connector 60, includes multiple electrical connector pins (unnamed). The electrical connector pins of the first logic connector 70 are shorter than those of the second logic connector 60. This is because the first logic connector 70 connects the logic board 20 to the first power board 30, where the distance between the logic board 20 and the first power board 30 is relatively short in the assembled state of the electronic control unit 100. However, the distance between the logic board 20 and the second power board 40 connected via the second logic connector 60 is relatively long because the first power board 30 and the heat sink 50 are arranged in the middle, for example from... Figure 10 This can be seen in the assembled state of the electronic control unit 100.

[0066] Electrical connector pins are inserted into corresponding connector pin holes (unnamed) inside the logic board 20. Connector pin holes for each electrical connector pin are arranged at two opposite ends of the logic board 20. Therefore, the first logic connector 70 and the second logic connector 60 are arranged at two opposite ends of the logic board 20. Furthermore, the logic board 20 includes connection pin holes (unnamed) for corresponding first connection pins (unnamed) of the first logic connector 70 and corresponding second connection pins (unnamed) of the second logic connector 60. The two logic connectors 60 and 70 are securely fixed to the logic board 20 via the connection pins.

[0067] Electrical connector pins are arranged in the logic connector housings 71 and 61 of the first logic connector 70 and the second logic connector 60. In this particular embodiment, the second logic connector housing 61 consists of two separate parts. This design is chosen due to the long extension of its electrical connector pins. The first part of the second logic connector housing 61 includes connection pins for corresponding connection pin holes in the logic board 20, and the second part of the second logic connector housing 61 includes connection pins for fixing in corresponding connection pin holes in the second power board 40. Furthermore, the first logic connector housing 71 includes connection pins for fixing in corresponding connection pin holes in the first power board 30.

[0068] As shown in the figure, the logic board 20 has cutouts at its edges for arches 18.1, 18.2, and 18.3, which extend from the connector board 10 toward and beyond the logic board 20. These arches 18.2 and 18.3 allow the heat sink 50 to be fastened to the connector board 10, thereby sandwiching the logic board 20 and the first power board 30 in the middle, as will be explained later. The interior of the arches 18.2 and 18.3 may have molded holes. These molded holes may be pre-threaded for bolts 1, or threaded connections via self-tapping screws or screws 1.

[0069] The first power connectors 17.1 and 17.2 extend from the connector board 10 through a cutout (unnamed) at the edge of the logic board 20 toward the first power board 30. In addition, the second power connectors 16.1 and 16.2 extend from the connector board 10 adjacent to the logic board 20 and the first power connectors 17.1 and 17.2 toward the second power board 40.

[0070] Figure 5 The assembly of the first power board 30 with the logic board 20 and the connector board 10 is shown.

[0071] The first electric motor connector 80 includes three first phase pins 82.1, 82.2, and 82.3 for electrical connection with the electric motor of the electric power steering system 200. The three first phase pins 82.1, 82.2, and 82.3 are received in a first electric motor connector housing 81. The first electric motor connector housing 81 includes connection pins (unnamed) for connection with corresponding connection pin holes (unnamed) in the first power board 30. Furthermore, the three first phase pins 82.1, 82.2, and 82.3 include, at their ends opposite to the ends for connection with the corresponding electric motor pins (unshown), a plurality of first power board connection pins (unshown) for electrical connection with the first power board 30.

[0072] The first logic connector 70 is connected to the first power board 30. In addition, the second power connectors 16.1 and 16.2 are guided through the first power board recesses 32.1 and 32.2 of the first power board 30.

[0073] The first electric motor connector 80 is arranged adjacent to the second logic connector 60, so that they can extend together along the heat sink cutout 53, as... Figure 6 As shown in the heat sink 50. The first electronic component 31 of the first power board 30 extends toward the heat sink 50 and is arranged on the top side of the first power board 30.

[0074] Figure 6 The radiator 50 is shown in more detail from the bottom side. A radiator edge 59 surrounds the radiator 50. The radiator 50, particularly the radiator edge 59, includes a groove 51 for pressing the housing 210 of the electric power steering system 200 into the groove 51. Thus, the housing 210 is mechanically secured to the radiator 50 and ultimately to the electronic control unit 100. Furthermore, the radiator 50 is thermally connected to the housing 210, allowing heat generated by the two power boards 30, 40 to be dissipated through the radiator 50 along the housing 210, which has a larger heat dissipation surface area. Additionally, the surface area of ​​the housing 210 can be thermally connected to the environment, thereby cooling the housing 210, or in other words, exchanging heat with the environment.

[0075] The groove 51 is a circumferential groove arranged around the circumference of the radiator edge 59. The radiator edge 59 further includes two circumferential outer surfaces 58.1 and 58.2, with the circumferential groove 51 provided between these two circumferential outer surfaces. The two circumferential outer surfaces 58.1 and 58.2 of the radiator edge 59 are configured to contact the inner surface 211 of the housing 210, as can be seen in Figure 17. For this purpose, the outer diameter of the circumferential outer surfaces 58.1 and 58.2 is equal to or substantially equal to the inner diameter of the inner surface 211 of the housing 210.

[0076] The following will refer to Figure 7 and Figure 8 Further explanation of the structure of radiator 50, Figure 7 The process of assembling the heat sink 50 with the first power board 30, which is assembled with the logic board 20 and the connector board 10, is shown. Figure 8 It shows that according to Figure 7 Components of the process. Figure 7 and Figure 8 The top side of the radiator 50 is shown, while Figure 6 The bottom side of the radiator 50 is shown.

[0077] The heat sink 50 is configured as a circular heat plate, wherein the heat sink 50 includes a heat sink cutout 53. The heat sink cutout 53 extends from the heat sink edge 59 into the interior of the heat sink 50. A second logic connector 60 and a first electric motor connector 80 extend through the heat sink cutout 53 in the assembled state, in which the heat sink 50 is connected to the first power board 30, as shown below. Figure 9 As shown.

[0078] Furthermore, the heat sink 50 includes several heat-conducting surfaces 52 on its bottom and top sides for connection to the first power board 30 and the second power board 40, particularly the first electronic component 31 and the second electronic component 41, via a thermal interface material (not shown). The heat-conducting surfaces 52.1 and 52.2 on the bottom side and the heat-conducting surface 52.3 on the top side... Figure 6 and Figure 8 This is illustrated by example. Figure 8 In its assembled state, the first electronic component 31 of the first power board 30 is in direct contact with the heat-conducting surfaces 52.1 and 52.2 on the bottom side of the heat sink 50 via a thermal interface material. The heat-conducting surfaces 52.1 and 52.2 on the bottom side are arranged at different heights along the thickness of the heat sink 50, thereby accommodating or connecting first electronic components 31 of different sizes or heights. The same applies to the top side, allowing the heat-conducting surface 52 on the top side of the heat sink 50 to be arranged at different heights along the thickness of the heat sink 50. Thus, the first electronic component 31 effectively transfers heat to the heat sink 50.

[0079] In addition, the radiator 50 includes radiator through holes 54.1, 54.2, and 54.3, such as... Figure 10 From the bottom side and Figure 11 As can be seen from the top side, the first power board 30 is secured by bolts 1 that pass through the heat sink through-hole 54 and are fixed in the arched portions 18.1 and 18.2 of the connector board 10. The bolts 1 further pass through the power board through-holes 33.1, 33.2 and 33.3 of the first power board 30, as shown in the figure.

[0080] Additionally, the heat sink 50 includes a heat sink recess 15 for guiding the second power connectors 16.1 and 16.2 of the connector board 10 through. This allows the second power connectors 16.1 and 16.2 to connect to the second power board 40 when the heat sink 50 is connected to the first power board 30.

[0081] In addition, the heat sink 50 includes heat sink protrusions 57.1, 57.2, and 57.3 extending from the heat sink 50, which extend beyond the two power boards 30 and 40 in the assembled state of the electronic control unit 100, such as... Figure 10As can be seen, these radiator protrusions 57.1, 57.2, and 57.2 can be arranged to rest on the inner edge 212 inside the housing 210 of the electric power steering system 200.

[0082] The heat sink 50 also includes heat sink holes 56.1, 56.2, and 56.3 on its top side. The second power board 40 can be fixed to the heat sink 50 by bolts 1 in the heat sink holes 56.1, 56.2, and 56.3. The heat sink holes 56.1, 56.2, and 56.3 can be pre-threaded or threaded by self-tapping screws or screws 1.

[0083] Figure 9 The electronic control unit 100 in its assembled state is shown. A second power board 40 with a second electronic component 41 on its bottom side is connected to a heat-conducting surface 52 on the top side of a heat sink 50. A second electric motor connector 90 includes three second phase pins 92.1, 92.2, and 92.3, which are arranged in a second electric motor connector housing 91. The second electric motor connector housing 91 includes further connection pins for connection to a sixth connection pin hole in the second power board 40.

[0084] Furthermore, the three second electrical phase pins 92.1, 92.2, and 92.3 include, at their ends opposite to the ends for connecting to the corresponding electric motor pins (not shown) of the electric motor, a plurality of second power board connection pins for electrical connection to the second power board 40. Additionally, the second electric motor connector housing 91 includes a second electric motor connector housing through-hole for guiding the bolt 1 through it to connect the second power board 40 to the heat sink holes 56.1 and 56.3 of the heat sink 50 via the second electric motor connector housing 91.

[0085] Further bolts 1 are guided through corresponding through holes in the second power board 40 for connection to heat sink holes 56.2, 56.4 of the heat sink 50. Here, the second power board 40 is connected to the top side of the heat sink 50 with its bottom side. The second power board 40 also includes second power board recesses 42.1, 42.2, 42.3 through which the first electrical phase pins 82.1, 82.2, 82.3 of the first electric motor connector 80 are guided.

[0086] All bolts 1 are tightened, securing the second power board 40 to the heat sink 50, which in turn secures the heat sink 50 to the connector board 10. The heat sink 50 is thus sandwiched between the first power board 30 and the second power board 40. The logic board 20 is sandwiched between the first power board 30 and the heat sink 50. Electrical phase pins 82.1, 82.2, 82.3, 92.1, 92.2, and 92.3 extend from the second power board 40, specifically beyond the heat sink protrusions 57.1, 57.2, and 57.3, allowing connection to the motor pins of the electric motor. After inserting the electronic control unit 100 into the housing 210, ventilation elements can be inserted into the vent 13.

[0087] Figure 10 The process of inserting the electronic control unit 100 into the housing 210 of the electric power steering system 200 is shown. During this process, the radiator protrusions 57.1, 57.2, and 57.3 act as guides.

[0088] Figure 11 A cross-section is shown through a portion of the electric power steering system 200 having a housing 210. The housing 210 is not yet pressed into the groove 51 of the radiator 50. However, the pressing operation is indicated by an arrow pointing in the direction of the force F of the pressing operation. Therefore, the housing 210 is plastically deformed and extends into the groove 51 of the radiator 50. The radiator 50 and the housing 210 are thus connected to each other and thermally bonded.

[0089] Furthermore, the circumferential outer surfaces 58.1 and 58.2 of the heat sink 50 are connected to the inner surface 211 of the housing 210 for thermal connection, allowing the heat sink 50 to dissipate the heat generated by the two power boards 30 and 40 connected to the heat sink 50 into the environment through the housing 210. Additionally, the heat sink protrusions 58.1, 58.2, and 58.3 can be arranged to rest on the inner edge 212 inside the housing 210.

[0090] The housing 210 is further sealed by a circumferential seal 12 of the connector plate 10 of the electronic control unit 100 abutting against its inner surface 211. The connector plate 10 is therefore designed as a cover for the housing 210. Furthermore, as can be seen from this cross-sectional view, the first electrical phase pins 82.1, 82.2, and 82.3 are electrically connected to the electric motor pins of the electric motor of the electric power steering system 200.

[0091] List of reference numerals

[0092] 10: Connector board

[0093] 11: Plug Connector

[0094] 12: Seals

[0095] 13: Ventilation opening

[0096] 15: Signal Connector

[0097] 16: Second power connector

[0098] 17: First power connector

[0099] 18: Arched section

[0100] 20: Logic Board

[0101] 21: First electronic component

[0102] 30: First power board

[0103] 31: Second electronic component

[0104] 32: First power board recess

[0105] 33: Power board through hole

[0106] 40: Second power board

[0107] 41: Third electronic component

[0108] 42: Second power board recess

[0109] 50: Radiator

[0110] 51: Groove

[0111] 52: Thermal conductive surface

[0112] 53: Radiator cutout

[0113] 54: Radiator through-hole

[0114] 55: Radiator recess

[0115] 56: Radiator holes

[0116] 57: Radiator protrusion

[0117] 58: Circumferential outer surface

[0118] 59: Radiator edge

[0119] 60: Second logic connector

[0120] 61: Second logic connector housing

[0121] 70: First Logic Connector

[0122] 71: First logic connector housing

[0123] 80: First electric motor connector

[0124] 81: First electric motor connector housing

[0125] 82: First electrical phase pin

[0126] 90: Second electric motor connector

[0127] 91: Second electric motor connector housing

[0128] 92: Second phase pin

[0129] 100: Electronic Control Unit

[0130] 200: Electric power steering system

[0131] 210: Shell

[0132] 211: Inner surface

[0133] 212: Inner Edge

[0134] F: Force

Claims

1. An electronic control unit (100) for an electric power steering system (200), the electric power steering system (200) including a housing (210) and an electric motor, the electronic control unit (100) being configured to be disposed within the housing (210) and electrically connected to the electric motor, wherein, The electronic control unit (100) includes: a first power board (30) having a first electric motor connector (80) for electrical connection with an electric motor; and a second power board (40) having a second electric motor connector (90) for electrical connection with an electric motor, wherein the connector board (10) of the electronic control unit (100) is electrically connected to the first power board (30) via at least one first power connector (17) and to the second power board (40) via at least one second power connector (16) by means of at least one plug connector (11), wherein the at least one first power connector (17) is shorter than the at least one second power connector (16). The electronic control unit (100) includes a heat sink (50) sandwiched between a first power board (30) and a second power board (40). The radiator (50) includes a radiator cutout (53) that extends from the edge (59) of the radiator into the interior of the radiator (50).

2. The electronic control unit (100) according to claim 1, wherein, The connector board (10) is connected to the first power board (30) via two first power connectors (17) and to the second power board (40) via two second power connectors (16), wherein the two first power connectors (17) are shorter than the two second power connectors (16).

3. The electronic control unit (100) according to claim 1 or 2, wherein, The at least one first power connector (17) and / or the at least one second power connector (16) are configured as metal strips.

4. The electronic control unit (100) according to claim 1 or 2, wherein, The length of the at least one second power connector (16) is at least 120% of the length of the first power connector (17).

5. The electronic control unit (100) according to claim 1 or 2, wherein, Each of the first power board (30) and the second power board (40) is provided with three-phase power to supply three-phase power to the electric motor.

6. The electronic control unit (100) according to claim 1 or 2, wherein, The logic board (20) is sandwiched between the first power board (30) and the connector board (10).

7. The electronic control unit (100) according to claim 1 or 2, wherein, The first power board (30) includes at least one first power board recess (32), and the at least one second power connector (16) extends through the at least one first power board recess to the second power board (40).

8. The electronic control unit (100) according to claim 1 or 2, wherein, The radiator (50) includes a radiator through hole (54), and the first power board (30) is fixed to the radiator (50) by a bolt (1) passing through the radiator through hole (54) and being fixed in an arch (18) extending from the connector board (10).

9. The electronic control unit (100) according to claim 1 or 2, wherein, The radiator (50) includes a radiator hole (56), and the second power board (40) is fixed to the radiator (50) by a bolt (1) fixed in the radiator hole (56).

10. The electronic control unit (100) according to claim 1 or 2, wherein, The heat sink (50) includes at least one heat sink recess (55) for the at least one second power connector (16) for the electronic control unit (100), the at least one second power connector (16) extending from the connector plate (10) through the at least one heat sink recess (55) inside the heat sink (50) to the second power plate (40).

11. The electronic control unit (100) according to claim 6, wherein, The second logic connector (60) extends from the logic board (20) through the heat sink cutout (53) to the second power board (40).

12. The electronic control unit (100) according to claim 1 or 2, wherein, The first electric motor connector (80) from the first power board (30) extends through the radiator cutout (53) for connection to the electric motor of the electric power steering system (200).

13. The electronic control unit (100) according to claim 1 or 2, wherein, The radiator (50) includes a radiator protrusion (57) extending beyond the first power plate (30) and the second power plate (40) and arranged to rest on the inner edge (212) of the housing (210) of the electric power steering system (200).

14. An electric power steering system (200), comprising an electronic control unit (100) according to any one of claims 1 to 13, wherein, The electric motor of the electric power steering system (200) is electrically connected to the first power board (30) through the first electric motor connector (80) and to the second power board (40) through the second electric motor connector (90).

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