Drive device

Abstract

A drive device (1) is provided with a motor (10) and a controller (50). A motor (10) includes a motor housing (15, 20, 30, 35) having a cylindrical motor case (16, 23, 33), a stator (12) fixed to the motor housing (15, 20, 30, 35), a motor wire (11) wound around the stator (12), a rotor (13) rotating by energizing the motor wire (11), and a shaft (14) rotating integrally with the rotor (13). The controller (50) has a substrate (53) on which electronic components (54, 55) related to the drive control of the motor (10) are mounted, and a controller housing (60) that accommodates the substrate (53), and is provided on one side of the motor (10) in the axial direction. The controller housing (60) closes the end of the motor housing (16, 23, 33) on the controller (50) side.

Description

[0001] Cross-reference of related applications

[0002] This application is based on Japanese Patent Application No. 2023-116748, filed on July 18, 2023, the contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a drive device. Background Technology

[0004] Previously, it was known that the control device was integrally formed on one side of the motor axis in an electromechanical integrated motor. For example, in Patent Document 1, the cover, frame, and motor housing were bonded together by a seal.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent document 1: Japanese Patent Application Publication No. 2017-17866.

[0008] For example, in a structure that uses seals and packaging components to prevent water droplets from penetrating the interior, as in Patent Document 1, there is a concern that the waterproof performance may be reduced if gaps are created due to long-term deterioration. Summary of the Invention

[0009] The purpose of this disclosure is to provide a drive device that can prevent water droplets or the like from entering the interior of the device.

[0010] The drive device disclosed herein includes a motor and a controller. The motor includes: a motor housing having a cylindrical motor casing, a stator fixed to the motor housing, motor wires wound on the stator, a rotor that rotates by energizing the motor wires, and a shaft that rotates integrally with the rotor.

[0011] The controller has a base plate on which electronic components related to the drive control of the motor are mounted, and a controller housing that houses the base plate. The controller is located on one side of the motor's axial direction. The controller housing closes the controller-side end of the motor housing. This prevents water droplets and the like from entering the device. Attached Figure Description

[0012] The above-mentioned and other objects, features, and advantages of this disclosure will become more apparent from the accompanying drawings and the following detailed description.

[0013] Figure 1 This is a schematic structural diagram of the steering system according to the first embodiment.

[0014] Figure 2 This is a cross-sectional view of the drive device according to the first embodiment.

[0015] Figure 3 This is a schematic diagram illustrating the connection between the motor housing and the ECU housing in the first embodiment.

[0016] Figure 4 This is a flowchart illustrating the assembly process of the drive device according to the first embodiment.

[0017] Figure 5 This is an explanatory diagram illustrating the assembly of the motor housing and stator according to the first embodiment.

[0018] Figure 6 This is an explanatory diagram illustrating the assembly of the rotor assembly according to the first embodiment.

[0019] Figure 7 This is an explanatory diagram illustrating the assembly of the motor assembly according to the first embodiment.

[0020] Figure 8 This is an explanatory diagram illustrating the assembly of the ECU housing and ECU-assembly into the motor assembly according to the first embodiment.

[0021] Figure 9 This is a cross-sectional view of the drive device according to the second embodiment.

[0022] Figure 10 This is a flowchart illustrating the assembly process of the drive device according to the second embodiment.

[0023] Figure 11 This is an explanatory diagram illustrating the formation of the motor housing according to the second embodiment.

[0024] Figure 12 This is an explanatory diagram illustrating the assembly of the ECU housing to the motor assembly according to the second embodiment.

[0025] Figure 13 This is a cross-sectional view of the drive device according to the third embodiment.

[0026] Figure 14 This is a flowchart illustrating the assembly process of the drive device according to the third embodiment.

[0027] Figure 15 This is an explanatory diagram illustrating the assembly of the inner shell according to the third embodiment.

[0028] Figure 16 This is an explanatory diagram illustrating the formation of the motor housing and the assembly of the ECU housing to the motor housing according to the third embodiment.

[0029] Figure 17 This is a cross-sectional view of the drive device according to the fourth embodiment. Detailed Implementation

[0030] The driving device of this disclosure will now be described with reference to the accompanying drawings. In several embodiments, substantially identical structures will be labeled with the same reference numerals and their descriptions will be omitted.

[0031] (First Implementation)

[0032] exist Figures 1 to 8 The first embodiment is shown in the figure. For example... Figure 1 As shown, the drive unit 1 includes a motor 10 and an ECU 50 as a controller, and the drive unit 1 is applied to an electric power steering system 8. Figure 1 This describes the structure of a steering system 90 equipped with an electric power steering device 8. The steering system 90 includes a steering wheel 91 as a steering component, a steering shaft 92, a pinion 96, a rack and pinion 97, wheels 98, and the electric power steering device 8.

[0033] The steering wheel 91 is connected to the steering shaft 92. A torque sensor 94 for detecting steering torque is installed on the steering shaft 92. A pinion 96 is installed at the top of the steering shaft 92. The pinion 96 meshes with the rack shaft 97. The two ends of the rack shaft 97 are connected to a pair of wheels 98 via steering tie rods, etc.

[0034] When the driver rotates the steering wheel 91, the steering shaft 92 connected to the steering wheel 91 rotates. The rotational motion of the steering shaft 92 is converted into linear motion of the rack shaft 97 via the pinion 96. The pair of wheels 98 are steered at an angle corresponding to the displacement of the rack shaft 97.

[0035] The electric power steering system 8 includes a drive unit 1 and a reduction gear 89, which serves as a power transmission unit that reduces the rotation of the motor 10 and transmits it to the steering shaft 92. That is, the electric power steering system 8 of this embodiment is a so-called "column-assisted type," where the steering shaft 92 can be considered the driving object. It could also be a so-called "rack-assisted type," where the rotation of the motor 10 is transmitted to the rack shaft 97.

[0036] Motor 10 is, for example, a three-phase brushless motor. Motor 10 outputs part or all of the torque required for steering, driven by a battery (not shown), which supplies power to rotate the reduction gear 89 in both directions. The drive unit 1 has an ECU 50 mounted on one side of the axial direction of motor 10, making it a so-called "mechatronic type." By being mechatronic, motor 10 and ECU 50 can be efficiently configured in vehicles with limited space. Hereinafter, the axial and radial directions in motor 10 will be appropriately referred to simply as "axial" and "radial." Furthermore, Figure 2 The bottom side of the paper in the figure is used as the output side.

[0037] like Figure 2As shown, the motor 10 includes a stator 12, a rotor 13, a shaft 14, and a motor housing 15. The stator 12 is fixed to the motor housing 15 and has motor wire 11 wound around it. Besides... Figure 2 Except for the motor line 11, the diagram is omitted. The rotor 13 is disposed radially inside the stator 12 and is configured to be rotatable relative to the stator 12.

[0038] Shaft 14 is embedded in rotor 13 and rotates integrally with rotor 13. Shaft 14 is rotatably supported on motor housing 15 by bearings 141 and 142. The end of shaft 14 on the ECU 50 side protrudes from motor housing 15 toward ECU 50, and a sensor magnet 145 is provided at this end. The end of shaft 14 opposite to ECU 50 is the output end, and a pulley 147 is provided at this end, which is connected to reduction gear 89.

[0039] The motor housing 15 includes a motor housing 16, a front frame 17, and a rear frame 18. The motor housing 16 is formed into a cylindrical shape, for example, from aluminum. The motor housing 16 is integrally formed with the front frame 17 on the output end side, and the motor housing 16 is integrally formed with the ECU housing 61 (described later) on the ECU 50 side. In this specification, the state in which at least one pre-formed component A is embedded to form component B is referred to as "integral molding" or "formed as an integrally molded article." Components A and B can be made of the same material or different materials.

[0040] The front frame 17 is formed of, for example, phenolic resin, and seals the output end of the motor housing 16. A bearing retainer 171, an outer wall abutment 172, and a flange 175 are formed on the front frame 17. A bearing 141 is provided in the bearing retainer 171.

[0041] The outer wall abutment portion 172 is formed in a cylindrical shape extending further towards the ECU 50 than the radially inward side of the outer peripheral wall of the motor housing 16. By providing the outer wall abutment portion 172, water droplets and the like are prevented from entering the device from the connection between the motor housing 16 and the front frame 17. Multiple flange portions 175 protrude radially outward and are mounted to the gearbox by fastening components such as screws (not shown). It can also be mounted on a housing other than the gearbox.

[0042] The rear frame 18 is formed into a generally circular plate shape, for example, from phenolic resin, and is fixed to the ECU50 side of the motor housing 16. A bearing 142 is fixed to the rear frame 18. Frames 17 and 18 hold bearings 141 and 142, and can also be considered as bearing retaining components.

[0043] The ECU 50 includes a base plate 53, a connector 57, and an ECU housing 60. The base plate 53 is formed to extend radially outward beyond the area defined by the axial projection of the motor housing 16, i.e., the motor area, and is fixed to the ECU housing 60 by fastening components 59 such as self-tapping screws. As fastening components, components other than self-tapping screws can also be used; for example, the base plate 53 can be fixed to the ECU housing 60 by resin riveting. Hereinafter, the side of the base plate 53 facing the motor 10 will be referred to as the motor surface 531, and the side opposite to the motor 10 will be referred to as the cover surface 532.

[0044] The leads 115 taken from each phase of the motor line 11 are formed to extend toward the ECU 50 side and are electrically connected to the substrate 53 in the motor area. In this embodiment, the leads 115 are brazed to the substrate 53, but as long as an electrical connection is achieved, the connection method is not limited to brazing. For example, a flexible connection based on crimping or a solderless connection using a socket connector can also be used.

[0045] Various electronic components, such as a heating element 54, a capacitor 55, and a rotation angle sensor 56, are mounted on the substrate 53. In this embodiment, the heating element 54 and the capacitor 55 are mounted on the cover surface 532 of the substrate 53. The heating element 54 includes a switching element of an inverter that switches the energization of the motor line 11, a motor relay, and a power relay. The rotation angle sensor 56 is mounted on the motor surface 531 opposite to the sensor magnet 145, and detects the rotation of the motor 10 by detecting the rotating magnetic field of the sensor magnet 145. Furthermore, illustrations of the rotation angle sensor 56 are omitted in the assembly description, etc.

[0046] Connector 57 is disposed on the motor surface 531 side of substrate 53 outside the motor area, and connector terminal 571 is connected to substrate 53. A flange portion 575 extending from the main body to the outer periphery is formed at the end of connector 57 on the substrate 53 side. The flange portion 575 is formed in an L-shaped cross section such that its top protrudes toward the side opposite to substrate 53.

[0047] The ECU housing 60 has an ECU housing 61 and an ECU cover 71, with a radial portion of the ECU housing 60 extending outward to the outside of the motor region. The ECU housing 61 is formed, for example, from epoxy resin and is a generally bottomed cylindrical shape that opens to the side opposite to the motor 10. The ECU housing 61 is integrally formed with the motor housing 16 and closes the end of the motor housing 16 on the ECU 50 side.

[0048] like Figure 3As shown, a closed hole 162 extending along the thickness direction is formed in the motor housing 16. Multiple closed holes 162 are formed separately in the circumferential direction at the portion integrally formed with the ECU housing 61. When the motor housing 16 and the ECU housing 61 are integrally formed, the ECU housing 61 is formed by inserting its radially inner and outer sides into the end of the motor housing 16 on the ECU 50 side. Here, the resin of the ECU housing 61 enters the closed hole 162, thereby improving the adhesive strength.

[0049] Similarly, at the portion of the motor housing 16 integrally formed with the front frame 17, a plurality of closed holes 163 extending along the thickness direction are also formed separately in the circumferential direction. When the motor housing 16 and the front frame 17 are integrally formed, the resin of the front frame 17 enters the closed holes 163, thereby improving the bonding strength.

[0050] return Figure 2 The ECU housing 61 has an outer wall abutment portion 611, a through hole 612, a base plate holding portion 613, a connector mounting portion 614, and a connector insertion hole 615 (see reference). Figure 8 )wait.

[0051] The outer wall abutment portion 611 is formed in a cylindrical shape along the outer peripheral wall of the motor housing 16, extending further towards the output end than the radially inward side. By providing the outer wall abutment portion 611, water droplets and the like are prevented from entering the device from the connection between the motor housing 16 and the ECU housing 61. Alternatively, the outer wall abutment portion 611 may not be provided, and at the connection between the motor housing 16 and the ECU housing 61, the axial length of the radially outer portion of the motor housing 16 is less than or equal to the radially inner axial length. The outer wall abutment portion 172 of the front frame 17 is similarly provided. Furthermore, in... Figure 2 Apart from that, the description of the outer wall contact part 611 is omitted.

[0052] The through hole 612 is configured to extend axially at a position corresponding to the shaft 14, and a sensor magnet 145 is disposed inside it. A substrate holding portion 613 is formed in the motor area, and the substrate 53 is fixed thereto by a fixing member 59. A connector 57 is mounted in the connector mounting portion 614 using adhesive or the like. Specifically, with the main body of the connector 57 inserted through the connector insertion hole 615 and the interface surface exposed, the connector 57 is mounted to the ECU housing 61 by inserting the flange portion 575 into the connector mounting portion 614, which is coated with adhesive.

[0053] The ECU cover 71 is formed of, for example, epoxy resin and is disposed on the cover surface 532 side of the substrate 53. The ECU cover 71 is integrally formed with the ECU housing 61, and the substrate 53 and the heat-generating element 54 and capacitor 55 mounted on the cover surface 532 side of the substrate 53 are sealed with resin. On the ECU cover 71, in the area formed by projecting the area where the heat-generating element 54 is mounted axially, i.e., the element mounting area, heat dissipation fins 711 are formed.

[0054] based on Figure 4 Flowchart and Figures 5-8 The assembly process of the drive device 1 in this embodiment will be explained. Hereinafter, the "steps" such as step S10 will be omitted and simply referred to as "S".

[0055] like Figure 5 As shown, in S10, the front frame 17 and the motor housing 16 are integrally formed. In S11, the stator 12 is hot-pressed onto the motor housing 16. Figure 6 As shown, in S12, the bearing 142 is fixed to the rear frame 18 by riveting, pressing, etc. In S13, the bearings 141 and 142 are pressed into the rotor assembly, which is formed by pressing the shaft 14 into the rotor 13. Furthermore, S10, S11 and S12, S13 can be interchanged or performed simultaneously.

[0056] like Figure 7 As shown, in S14, Figure 6 The rotor assembly, in the state shown on the right side of the paper, is assembled on... Figure 5 The motor housing 16 is shown on the right side of the paper. Specifically, the rear frame 18 is heat-pressed into the motor housing 16. The bearing 141 is inserted into the bearing retainer 171 of the front frame 17. In S15, the pulley 147 is pressed into the output end of the shaft 14, and the sensor magnet 145 is pressed into the ECU 50 end of the shaft 14. Hereinafter, the state in which the stator 12, the front frame 17, and the rear frame 18 are assembled into the motor housing 16 is referred to as the motor assembly.

[0057] like Figure 8 As shown, in S16, in the state of the motor assembly, the ECU housing 61 and the motor housing 16 are resin molded into one piece (see reference). Figure 8 (Left side of the paper). In S17, adhesive is applied to the connector mounting portion 614 of the ECU housing 61. In S18, the ECU assembly with connector 57 assembled is assembled to the ECU housing 61 (see reference). Figure 8 (Right side of the paper).

[0058] In S19, lead 115 is electrically connected to substrate 53. Furthermore, if the connection between lead 115 and substrate 53 is a crimp connection or other non-soldering connection, the connection is completed in S18 when the ECU-assembly is assembled onto the ECU housing 61, therefore S19 is omitted. In S20, the ECU-assembly is sealed with resin to form ECU cover 71 (see reference). Figure 2 In the diagram, the rotor assembly is appropriately designated as "RA", the motor assembly as "MA", and the ECU-assembly as "EA".

[0059] For example, as a comparative example, if the rear frame is used as a metal heat sink and the heat of the heating element 54 is dissipated to the motor housing 16 side, the heating element 54 needs to be mounted on the motor surface 531 side of the substrate 53 and installed in the motor area.

[0060] In contrast, in the drive device 1 of this embodiment, the heating element 54 is resin-embedded in the ECU cover 71, and the heating element 54 dissipates heat through air radiation via the ECU cover 71 in direct contact. This allows the heating element 54 to be mounted on the cover surface 532 side or outside the motor area, increasing the flexibility of the substrate design. Furthermore, intermediate materials such as thermal gel, which are required when dissipating heat to a metal heat sink, are not needed.

[0061] The ECU housing 61 is integrally molded with the motor housing 16 via insert molding, thus sealing the ends of the motor housing 16. Similarly, the front frame 17 is integrally molded with the motor housing 16 via insert molding, also sealing the ends of the motor housing 16. This simple structure prevents water droplets and dust from entering the device without any areas prone to crevice corrosion. Furthermore, the connection between the ECU housing 61 and the front frame 17 and the motor housing 16 is sealed without adhesives or other sealants, preventing gaps from forming due to long-term deterioration of seals and maintaining waterproof performance over a long period. Moreover, the integrally molded ECU housing 61, front frame 17, and motor housing 16 are preferably made of materials with similar coefficients of linear expansion.

[0062] In this embodiment, the motor housing 16 is formed of metal, and the front frame 17 is formed of resin. In other words, instead of making the motor housing a bottomed cylindrical shape and forming the cylindrical portion and the side opposite to the ECU 50 into a single component, the cylindrical motor housing 16 and the generally circular front frame 17 are separated. The front frame 17 is formed from the end of the metal motor housing 16 using resin molding, thus making the motor housing 16 and the front frame 17 a single molded product. This allows the components to be separated without compromising corrosion resistance. Furthermore, by making it a different component from the motor housing 16, the front frame 17 is easier to form, and therefore a material with good corrosion resistance and low flowability can be used.

[0063] As described above, the drive unit 1 includes a motor 10 and an ECU 50. The motor 10 includes: a motor housing 15 having a cylindrical motor housing 16; a stator 12 fixed to the motor housing 15; motor wires 11 wound around the stator 12; a rotor 13 that rotates by energizing the motor wires 11; and a shaft 14 rotatably supported on the motor housing 15 and rotating integrally with the rotor 13.

[0064] The ECU 50 has a substrate 53 on which electronic components related to the drive control of the motor 10 are mounted, and an ECU housing 60 that houses the substrate 53. The ECU 50 is located on one side of the motor 10 along its axial direction. The electronic components include a heating element 54 and a capacitor 55, etc. The ECU housing 60 closes the end of the motor housing 16 on the ECU 50 side. Specifically, the motor housing 16 and the ECU housing 61 are formed as a single molded piece, and the end of the motor housing 16 on the ECU 50 side is directly closed by the ECU housing 61.

[0065] This eliminates the gap between the motor housing 16 and the ECU housing 60, thus preventing water droplets or foreign objects from entering the device from the connection between the motor 10 and the ECU 50.

[0066] The motor housing 15 has a front frame 17 that closes the end of the motor housing 16 opposite to the ECU 50. This allows the front frame 17 to be formed without compromising corrosion resistance.

[0067] The ECU housing 60 clamps the radially inner and radially outer sides of the end of the motor housing 16 on the ECU 50 side. Additionally, the front frame 17 clamps the radially inner and radially outer sides of the end of the motor housing 16 on the side opposite to the ECU 50. By clamping the motor housing 16 radially from both sides using the resin ECU housing 61 or the front frame 17, the reliability of the connection can be improved.

[0068] At the connection point between the ECU housing 60 and the motor housing 16, the axial length of the ECU housing 60 is longer on the radially outer side than on the radially inner side of the motor housing 16. Similarly, at the connection point between the front frame 17 and the motor housing 16, the axial length of the front frame 17 is longer on the radially outer side than on the radially inner side. By providing the outer wall abutment portions 172 and 611 and forming a relatively longer axial length on the radially outer side, the intrusion of water droplets into the isotropic device can be further suppressed.

[0069] (Second Implementation)

[0070] exist Figures 9-12 The second embodiment is shown in the diagram. The main difference between the second to fourth embodiments is the motor housing; therefore, the description of the ECU50, etc., is omitted, and the description will focus on the structure related to the motor housing.

[0071] like Figure 9 As shown, the motor housing 20 of this embodiment has a front frame 21, a rear frame 22, and a motor housing 23. The front frame 21 has a bearing retaining portion 211, a stator abutment portion 212, and a plurality of flange portions 215. The front frame 21 is formed of a metal such as aluminum alloy and is provided on the side of the stator 21 opposite to the ECU 50.

[0072] The bearing retainer 221 holds the bearing 141. The stator abutment portion 212 is formed in a cylindrical shape along the inner peripheral wall of the motor housing 23. The flange portion 215 is formed protruding radially outward and is configured to be mounted to the housing by fastening components such as screws (not shown).

[0073] The rear frame 22 has a bearing retaining portion 221 and a stator abutment portion 222. The rear frame 22 is formed of a metal such as aluminum alloy and is disposed on the ECU50 side of the stator 12. The bearing 142 is fixed to the bearing retaining portion 221 by pressing or the like. The stator abutment portion 222 is formed in a cylindrical shape along the inner peripheral wall of the motor housing 23.

[0074] The motor housing 23 is formed into a generally cylindrical shape, for example, from phenolic resin. The motor housing 23 integrally molds the sides of the stator 12, the front frame 21, and the rear frame 22. A closed hole 231 extending along the thickness direction is formed at the connection point between the motor housing 23 and the ECU housing 61. The reliability of the connection is improved by allowing resin from the ECU housing 61 to enter the closed hole 231.

[0075] based on Figure 10 Flowchart, Figure 11 and Figure 12 This describes the assembly process of the motor assembly in this embodiment. Although the materials and shapes of the rear frame 22 differ from those in the first embodiment in processes S30 and S31, they are similar. Figure 4 The processes S12 and S13 are the same.

[0076] like Figure 11 As shown, in step S32, the front frame 21, stator 12, and rotor assembly are stacked. At this time, radially outward, starting from the output end side, the front frame 21, stator 12, and rear frame 22 are stacked in that order, with the stator abutment portion 212 of the front frame 21 and the stator abutment portion 222 of the rear frame 22 abutting against the stator 12. Thus, the axial position is positioned.

[0077] In step S33, the radially outer sides of the front frame 21, stator 12, and rear frame 22 are sealed with resin to form the motor housing 23. The processing from step S15 onwards is the same as in the first embodiment, such as... Figure 12 As shown, pulley 147 is pressed into the output end of shaft 14, and sensor magnet 145 is pressed into the ECU 50 side end of shaft 14. Then, ECU housing 61 and motor housing 23 are resin molded together. The assembly of ECU 50 is the same as in the above embodiment, so the description is omitted.

[0078] In this embodiment, the stator 12, front frame 21, and rear frame 22 are integrally sealed with resin by the motor housing 23. This improves the fixing force between the parts. In addition, the thickness required to ensure fixing strength can be reduced, thus contributing to the weight reduction of the drive unit 1. Furthermore, the stator 12 and the sides of the frames 21 and 22 can be molded together, and the motor housing 23 can be integrally formed, thereby preventing water droplets from entering the device without the use of seals or the like.

[0079] In this embodiment, the motor housing 23 is formed of resin. Specifically, the motor housing 20 has a front frame 21 disposed on one side of the stator 12 along its axial direction and a rear frame 22 disposed on the other side of the stator 12 along its axial direction. The motor housing 23 is formed radially outward in a configuration where the front frame 21, stator 12, and rear frame 22 are stacked axially. This allows for a more secure connection between the front frame 21, stator 12, and rear frame 22 and the motor housing 23, improving the reliability of the component connection. Furthermore, it achieves the same effects as the embodiment described above.

[0080] (Third implementation method)

[0081] exist Figures 13-16 The third embodiment is shown in the figure. The motor housing 30 of this embodiment has a front inner housing 31, a rear inner housing 32, and a motor housing 33.

[0082] The front inner housing 31 has a bearing retaining portion 311 and a stator retaining portion 312. The front inner housing 31 is formed, for example, by an aluminum alloy, into a generally bottomed cylindrical shape with an opening on the ECU 50 side. The bearing retaining portion 311 holds the bearing 141. The stator retaining portion 312 is formed into a cylindrical shape, and the end of the stator retaining portion 312 on the ECU 50 side is disposed between the stator 12 and the motor housing 33.

[0083] The rear inner housing 32 has a bearing retaining portion 321 and a stator retaining portion 322. The rear inner housing 32 is formed, for example, from an aluminum alloy, and is generally cylindrical with a bottom opening on the side opposite to the ECU 50. A bearing 142 is fixed in the bearing retaining portion 321. The stator retaining portion 322 is formed in a cylindrical shape. The end of the stator retaining portion 322 on the side opposite to the ECU 50 is located between the stator 12 and the motor housing 33, and the top surface of this end abuts against the front inner housing 31.

[0084] The motor housing 33 is formed into a generally cylindrical shape, for example, from phenolic resin. The motor housing 33 integrally forms the sides of the inner housings 31 and 32. A closed hole 331 extending along the thickness direction is formed at the connection point between the motor housing 33 and the ECU housing 61. Resin from the ECU housing 61 enters the closed hole 331, thereby improving the reliability of the connection. Multiple flanges 335 in the motor housing 33, for fixing to the housing by screws or other fasteners (not shown), are formed to protrude radially outwards.

[0085] based on Figure 14 Flowchart and Figure 15 and Figure 16 The assembly process of the motor assembly in this embodiment is explained. For example... Figure 15 As shown in the lower left of the paper, in S40, the stator 12 is heat-pressed onto the front inner housing 31 in such a way that the bearing retaining part 311 is opposite to the side from which the lead wire 115 of the stator 12 is led out. The front inner housing 31 and the stator 12 can also be fixed by methods other than heat pressing. The same applies to fixing the rear inner housing 32 to the stator 12.

[0086] like Figure 15 As shown on the upper side of the paper, in S41, bearing 142 is pressed into the rear inner housing 32, and in S42, bearings 141 and 142 are pressed into the rotor assembly. Figure 15 As shown in the lower right of the paper, in S43, the rear inner housing 32 covers the stator 12 and is thermo-pressed together by the rear inner housing 32 with its opening side facing the front inner housing 31. The abutting position of the inner housings 31 and 32 is sufficient to thermo-press the stator 12 onto both sides, and the abutting position of the inner housings 31 and 32 can also be offset from the center position of the stator 12 in the axial direction.

[0087] In S44, such as Figure 16 As shown, the front inner housing 31 and the rear inner housing 32 are resin-molded into one piece to form the motor housing 33. The processing from S15 onwards is the same as in the first embodiment: the pulley 147 is pressed into the output end of the shaft 14, and the sensor magnet 145 is pressed into the ECU 50 end of the shaft 14. Then, the ECU housing 61 and the motor housing 33 are resin-molded into one piece. The assembly on the ECU side is the same as in the above embodiment, so description is omitted.

[0088] In this embodiment, the stator 12 is fixed to the inner housings 31 and 32, and the outer side of the stator 12 is sealed with resin, thereby preventing water droplets and the like from entering the device without the use of seals. Furthermore, this improves reliability in terms of corrosion resistance.

[0089] In this embodiment, the motor housing 30 has a front inner housing 31 and a rear inner housing 32. The front inner housing 31 is fixed to the radially outer side of the stator 12 and is formed to extend axially toward one side of the stator 12. The rear inner housing 32 is fixed to the radially outer side of the stator 12 and is formed to extend axially toward the other side of the stator 12. The motor housing 33 is formed radially outside the front inner housing 31 and the rear inner housing 32. Therefore, the motor housing 33 can be formed relatively easily. Furthermore, it achieves the same effect as the embodiment described above.

[0090] (Fourth Implementation)

[0091] exist Figure 17 The fourth embodiment is shown. In this embodiment, the motor housing 35 includes a front inner housing 36, a front frame 37, a rear inner housing 32, and a motor housing 33. In this embodiment, the front frame 37, which has a bearing retaining portion 371 that holds the bearing 141, is formed separately from the front inner housing 36. During the assembly process, before the stator 12 is hot-pressed onto the front inner housing 36, the front frame 37 is fixed to the front inner housing 36 by hot-pressing, pressing, or the like. Subsequent assembly processes are the same as in the third embodiment.

[0092] In this embodiment, by making the front frame 37 and the front inner housing 36 separate, the front inner housing 36 can be formed by stamping, thereby improving productivity. Furthermore, it achieves the same effect as the embodiment described above.

[0093] In the implementation, the front frame 17 corresponds to "frame", the front frame 21 corresponds to "first frame", the rear frame 22 corresponds to "second frame", the front inner housing 31 corresponds to "first inner housing", the rear inner housing 32 corresponds to "second inner housing", the ECU 50 corresponds to "controller", and the ECU housing 60 corresponds to "controller housing".

[0094] (Other implementation methods)

[0095] In the above embodiments, examples are mainly shown of using phenolic resin as the material for the front and rear frames, and epoxy resin as the material for the controller housing. In other embodiments, the controller housing may also use materials other than epoxy resin. Additionally, the motor housing may also use materials other than phenolic resin; for example, to further improve heat dissipation, the rear frame may be made of a metal with good thermal conductivity, such as aluminum alloy. Furthermore, in the first embodiment, the motor housing may also be formed of resin. That is, it may also be "the drive device described in any one of embodiments 1 to 6, wherein the motor housing is formed of resin."

[0096] In the above embodiments, the motor housing and the front frame are integrally formed as different components. In other embodiments, the motor housing may be formed as a bottomed cylindrical shape with an opening on the ECU side, and the motor housing and the front frame may be formed as a single component. Additionally, the case where the motor housing is formed as a bottomed cylindrical shape is also included in the concept of a "cylindrical motor housing".

[0097] In the above embodiment, when the motor housing and the controller housing are integrally molded, the motor housing forms a closed opening and is integrally molded while being sandwiched between the inner and outer sides of the controller housing. In other embodiments, when the motor housing and the ECU housing are integrally molded, the inner and outer sides may not be sandwiched. Additionally, the closed opening may be omitted. The same applies to the connection between the motor housing and the front frame.

[0098] In the above embodiment, heat dissipation ribs are provided in the axial projection area of ​​the heat-generating component. In other embodiments, depending on the thermal mass of the controller housing, heat dissipation ribs may be omitted, or other structures for heat dissipation may be provided (e.g., a metal plate with good thermal conductivity, or a flow path for cooling fluid).

[0099] In the above embodiment, the connector is disposed on the motor side of the substrate, and the interface surface faces the output end side axially. In other embodiments, the connector may also be disposed on the cover surface of the substrate, and the orientation of the interface surface may also be different. Furthermore, multiple connectors may be disposed. Additionally, the component arrangement in the substrate may differ from the above embodiment. Moreover, as long as heat dissipation of the electronic components can be ensured, the electronic components may not need to be embedded in the controller housing.

[0100] In the above embodiment, the controller is formed to extend radially outward compared to the motor region. In other embodiments, the controller may also be disposed within the motor region. In the above embodiment, the drive unit is applied to an electric power steering system. In other embodiments, it may also be applied to an in-vehicle device other than an electric power steering system, or to a device outside of a vehicle.

[0101] The present disclosure is not limited to the above-described embodiments and can be implemented in various ways without departing from its spirit.

[0102] Although this disclosure is based on embodiments, it is not limited to those embodiments and structures. This disclosure also includes various modifications and equivalent variations. Furthermore, various combinations and methods, even those containing only one element, or more than one or fewer other combinations and methods, also fall within the scope and spirit of this disclosure.

Claims

1. A driving device, characterized in that, have: An electric motor (10) having a motor housing (15, 20, 30, 35), a stator (12), motor wires (11), a rotor (13), and a shaft (14), the motor housing having a cylindrical motor casing (16, 23, 33), the stator being fixed to the motor housing, the motor wires being wound around the stator, the rotor rotating by energizing the motor wires, and the shaft rotating integrally with the rotor; and A controller (50) having a base plate (53) and a controller housing (60) is disposed on one side of the axial direction of the motor. The base plate is equipped with electronic components (54, 55) related to the drive control of the motor, and the controller housing houses the base plate. The controller housing encloses the controller-side end of the motor housing.

2. The driving device according to claim 1, characterized in that, The controller housing clamps the radially inner and radially outer sides of the controller-side end of the motor housing.

3. The driving device according to claim 2, characterized in that, At the connection between the controller housing and the motor housing, the axial length of the controller housing is longer in the radially outer portion than in the radially inner portion of the motor housing.

4. The driving device according to any one of claims 1 to 3, characterized in that, The motor housing has a frame (17) that closes the end of the motor housing opposite to the controller.

5. The driving device according to claim 4, characterized in that, The frame clamps the radially inner and radially outer sides of the end of the motor housing opposite to the controller.

6. The driving device according to claim 5, characterized in that, have: At the connection between the frame and the motor housing, the axial length of the frame is longer on the radially outer side of the motor housing than on the radially inner side.

7. The driving device according to claim 6, characterized in that, The motor housing is made of resin.

8. The driving device according to claim 7, characterized in that, The motor housing (20) has a first frame (21) disposed on one side of the axial direction of the stator and a second frame (22) disposed on the other side of the axial direction of the stator. The motor housing (23) is formed on the radial outer side of the stacked state of the first frame, the stator and the second frame.

9. The driving device according to claim 7, characterized in that, The motor housing (30) has a first inner housing (31) and a second inner housing (32). The first inner housing is fixed to the radially outer side of the stator and is formed to extend to one side of the stator's axial direction. The second inner housing is fixed to the radially outer side of the stator and is formed to extend to the other side of the stator's axial direction. The motor housing (33) is formed on the radial outer side of the first inner housing and the second inner housing.

Images