Electrical device

Abstract

The invention provides electrical equipment. A housing of an electrical device according to the present specification is divided into a first housing and a second housing, one of which is provided with a plurality of terminals and the other of which is provided with a plurality of connectors, and a structure capable of mitigating a sudden change in resistance when the second housing is coupled to the first housing is provided. The first housing includes a first terminal, and the second housing includes a first connector. One of the first housing and the second housing is provided with a second terminal, and the other is provided with a second connector. When the second housing is brought close to the first housing, the first terminal is inserted into the first connector, and the second terminal is inserted into the second connector. A first stroke, which is the length of the first terminal inserted into the first connector, is longer than a second stroke, which is the length of the second terminal inserted into the second connector.

Description

Technical Field

[0001] The technology disclosed in this specification relates to electrical equipment. Background Technology

[0002] Japanese Patent Application Publication Nos. 2016-139539 and 2016-139540 disclose an electrical device that houses a motor and an inverter within a single housing. The housing is divided into a first housing and a second housing; the motor is housed in the first housing, and the inverter is housed in the second housing. Terminals are provided in the first housing, and connectors are provided in the second housing. When the second housing is joined to the first housing, the terminals and connectors engage. Summary of the Invention

[0003] When the first housing has multiple terminals, if all terminals simultaneously contact various connectors, the resistance when the second housing is joined to the first housing changes drastically. This specification provides a structure that can mitigate the drastic change in resistance when the second housing is joined to the first housing.

[0004] The electrical device disclosed in this specification comprises: a first housing having an opening; a second housing that is joined to the first housing to close the opening; a first terminal disposed in the first housing and extending in a direction of approach to the first housing along the second housing when the second housing is joined to the first housing; a first connector disposed in the second housing and coupled to the first terminal; a second terminal disposed in one of the first housing and the second housing and extending parallel to the first terminal; and a second connector disposed in the other of the first housing and the second housing and coupled to the second terminal. In the electrical device disclosed in this specification, the length of insertion of the first terminal into the first connector, i.e., the first stroke, is longer than the length of insertion of the second terminal into the second connector, i.e., the second stroke.

[0005] When the second housing is brought close to the first housing, the first terminal, with its longer travel, contacts the connector (first connector) first, before the second terminal. After the first terminal contacts the connector, the second terminal contacts the connector (second connector). Because the first and second terminals contact the connector sequentially, the change in resistance when joining the second housing to the first housing is mitigated.

[0006] The details of the technology disclosed in this specification and further improvements are described in the following "Detailed Description". Attached Figure Description

[0007] Figure 1 This is a cross-sectional view of the electrical equipment (motor unit) in the embodiment.

[0008] Figure 2 This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (with the second housing separated from the first housing).

[0009] Figure 3 This is a cross-sectional view of the electrical equipment (motor unit) in the embodiment (positioning pin in contact with positioning hole).

[0010] Figure 4 This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (the first terminal is in contact with the first connector).

[0011] Figure 5 This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (the second terminal is in contact with the second connector).

[0012] Figure 6 This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (with the second terminal block separated from the motor). Detailed Implementation

[0013] The electrical device of the embodiment will be described with reference to the accompanying drawings. The electrical device of the embodiment is a motor unit 10 in which an electric motor and an inverter are housed in a single housing.

[0014] Figure 1 This shows a cross-section of the motor unit 10. In the motor unit 10, the electric motor 130, inverter 230, and controller 240 are housed in a single enclosure. For ease of explanation, "electric motor 130" will be referred to as "motor 130" below. The structures of the motor 130, inverter 230, and controller 240 are not shown in the figure.

[0015] The housing is divided into a first housing 100 and a second housing 200. The first housing 100 has an opening 101, and the second housing 200 is joined to the first housing 100 to block the opening 101. The second housing 200 is fixed to the first housing 100 by bolts 109.

[0016] Motor 130 is housed in first housing 100. A gear set (not shown) is also housed in first housing 100. Motor unit 10 is a power unit mounted on an electric vehicle. The main shaft of motor 130 engages with the input gear of the gear set, and the output gear of the gear set engages with the axle. Components related to the electric vehicle are also omitted from the figures.

[0017] Inverter 230 and controller 240 are housed in second housing 200. Controller 240 uses information from sensors (described later) to determine the target output of motor 130 and controls inverter 230 based on the target output. Inverter 230 generates AC power to drive motor 130 based on instructions from controller 240.

[0018] Motor 130 includes sensor 140. Sensor 140 may be a decomposer for detecting the rotation angle of the rotor of motor 130, or an oil temperature sensor for measuring the internal oil temperature of motor 130, etc. Sensor 140 is electrically connected to controller 240 via a plurality of first terminals 111 and a first connector 210. The first connector 210 has the same number of first sockets 211 as the plurality of first terminals 111. The plurality of first terminals 111 are inserted into the first connector 210, and each first terminal 111 contacts its respective first socket 211. Sensor 140 is electrically connected to controller 240. Sensor signals are sent from sensor 140 to controller 240 via the first terminals 111 and first connector 210. Electricity representing sensor data flows through the first connector 210 and the plurality of first terminals 111.

[0019] Inverter 230 and motor 130 are electrically connected via a plurality of second terminals 121 and a second connector 220. The second connector 220 has the same number of second sockets 221 as the second terminals 121, and the second terminals 121 are inserted into the second connector 220, with each second terminal 121 contacting its respective second socket 221. Motor 130 is electrically connected to inverter 230. Inverter 230 generates AC power for driving motor 130, and this AC power is supplied to motor 130 via the plurality of second terminals 121 and the second connector 220. A large amount of power for driving motor 130 flows through the plurality of second terminals 121 and the second connector 220.

[0020] The power flowing through the first terminal 111 and the first connector 210 is less than the power flowing through the second terminal 121 and the second connector 220.

[0021] Multiple first terminals 111 are disposed on a first terminal block 110, which is fixed to the inner wall of the first housing 100. Furthermore, the connection between the first terminal block 110 and the first housing 100 is not visible in the figure. Multiple second terminals 121 are disposed on a second terminal block 120, which is fixed to the motor 130. That is, the first terminals 111 and the second terminals 121 are fixed to the first housing 100. In other words, the first terminals 111 and the second terminals 121 are disposed on the first housing 100.

[0022] The first connector 210 is fixed to the controller 240, and the second connector 220 is fixed to the inverter 230. That is, the first connector 210 and the second connector 220 are fixed to the second housing 200. In other words, the first connector 210 and the second connector 220 are disposed in the second housing 200.

[0023] Figure 2This shows a cross-section indicating the separation of the second housing 200 from the first housing 100. When the second housing 200 separates from the first housing 100, the first terminal 111 separates from the first connector 210, and the second terminal 121 separates from the second connector 220. During the manufacturing process of the motor unit 10, the second housing 200 is oriented along... Figure 2 The thick arrow line X approaches the first housing 100 and engages with it. The first terminal 111 and the second terminal 121 are along... Figure 2 The thick arrow line X extends in the direction of the second housing 200. In other words, the first terminal 111 and the second terminal 121 extend in the direction of approach of the second housing 200 to the first housing 100 when the second housing 200 is joined to the first housing 100. Therefore, during the process of joining the second housing 200 to the first housing 100, the first terminal 111 is joined to the first connector 210, and the second terminal 121 is joined to the second connector 220. However, the length of the first terminal 111 inserted into the first connector 210, i.e., the first stroke L1, is longer than the length of the second terminal 121 inserted into the second connector 220, i.e., the second stroke L2 (in... Figure 1 The diagram shows the first stroke L1 and the second stroke L2. This ensures that when the second housing 200 approaches the first housing 100, the first terminal 111 contacts the first connector 210 before the second terminal 121 contacts the second connector 220.

[0024] The second housing 200 is provided with a positioning pin 203 for relative positioning with the first housing 100, and the first housing 100 is provided with a positioning hole 103 for inserting the positioning pin 203. The positioning pin 203 extends along... Figure 2 The locating pin 203 extends in the direction indicated by the thick arrow X. In other words, the locating pin 203 extends along the approach direction of the second housing 200 when it is joined to the first housing 100. The locating pin 203, the first terminal 111, and the second terminal 121 extend in parallel.

[0025] The length of the positioning pin 203 inserted into the positioning hole 103, i.e., the third stroke L3, is longer than the length of the first terminal 111 inserted into the first connector 210, i.e., the first stroke L1. Figure 1 The diagram also illustrates the third stroke (L3). This means that when the second housing 200 approaches the first housing 100, the locating pin 203 contacts the locating hole 103 before the first terminal 111 contacts the first connector 210. That is, when the second housing 200 is joined to the first housing 100, the locating pin 203 contacts the locating hole 103 first, then the first terminal 111 contacts the first connector 210, and finally the second terminal 121 contacts the second connector 220. The relationship L3 > L1 > L2 ensures this contact sequence.

[0026] Figure 3This indicates that the separated second housing 200 is approaching the first housing 100, and the locating pin 203 is in contact with the locating hole 103. Arrow A indicates the contact point between the locating pin 203 and the locating hole 103. At this time, a distance B is ensured between the first terminal 111 and the first connector 210, and a distance C is ensured between the second terminal 121 and the second connector 220.

[0027] As the second housing 200 approaches the first housing 100, the front end of the positioning pin 203 inserts into the positioning hole 103, accurately determining the position of the second housing 200 relative to the first housing 100. Subsequently, the first terminal 111 contacts the first connector 210.

[0028] Figure 4 This indicates the state where the front end of the first terminal 111 is in contact with the first connector 210. Arrow D indicates the contact point between the first terminal 111 and the first connector 210. At this time, a distance E is ensured between the second terminal 121 and the second connector 220.

[0029] When the second housing 200 moves closer to the first housing 100, the front end of the first terminal 111 is inserted into the first connector 210, while the front end of the second terminal 121 contacts the second connector 220.

[0030] Figure 5 This indicates that the front end of the second terminal 121 is in contact with the second connector 220. Arrow F indicates the contact area between the second terminal 121 and the second connector 220. At this time, the front end of the first terminal 111 has been inserted into the first connector 210.

[0031] When the second housing 200 approaches the first housing 100 further, the flange of the second housing 200 contacts the flange of the first housing 100. Figure 1 This indicates the final state in which the second housing 200 is combined with the first housing 100.

[0032] As described above, when the second housing 200 is brought close to the first housing 100, firstly, the locating pin 203 contacts the locating hole 103; then, the first terminal 111 contacts the first connector 210; and finally, the second terminal 121 contacts the second connector 220. The relationship L3 > L1 > L2 ensures this contact sequence. The advantages of the sequential contact of the locating pin 203, the first terminal 111, and the second terminal 121 will be explained.

[0033] Before the first terminal 111 and the second terminal 121 contact the connector, the front end of the positioning pin 203 is inserted into the positioning hole 103. Before the first terminal 111 and the second terminal 121 contact the connector, the second housing 200 is accurately positioned relative to the first housing 100. Therefore, the first terminal 111 is reliably inserted into the first connector 210, and the second terminal 121 is reliably inserted into the second connector 220.

[0034] As the first terminal 111 and the second terminal 121 sequentially contact the connector, the resistance gradually increases when the second housing 200 approaches the first housing 100. If the first stroke and the second stroke are the same, then the first terminal 111 and the second terminal 121 simultaneously contact their respective connectors. As a result, the resistance changes drastically when the second housing 200 approaches the first housing 100. By making the first stroke L1 different from the second stroke L2, the drastic increase in resistance can be mitigated.

[0035] Furthermore, the power flowing through the first terminal 111 is lower than that flowing through the second terminal 121, and the first terminal 111 can be thinner and weaker than the second terminal 121. The resistance when inserting the first terminal 111 into the first connector 210 is less than the resistance when inserting the second terminal 121 into the second connector 220. This feature also has advantages. The first terminal 111 begins to be inserted into the first connector 210 before the second terminal 121 is inserted into the second connector 220. Then, even a slight change in resistance when the second housing 200 approaches the first housing 100 can detect an insertion error of the first terminal 111. In cases where the second terminal 121, with its higher resistance, contacts the connector first, the small change in resistance between the first terminal 111 and the first connector 210 may not be detected due to the higher resistance of the second terminal 121. By prioritizing the contact of the terminal with lower resistance with the connector, the sensitivity of insertion error detection can be improved.

[0036] Figure 6 This diagram shows the separation of the second terminal block 120 from the motor 130. A locating pin 123 is provided on the second terminal block 120, and a locating hole 124 is provided on the motor 130. The locating pin 123 and the locating hole 124 determine the precise position of the second terminal block 120 relative to the motor 130. The locating pin 123 and the locating pin 203 extend parallel to each other. Alternatively, the locating pin 203 and the locating pin 123 can be of the same size, and the locating hole 103 and the locating hole 124 can also be of the same size. This improves the processing efficiency of the locating pin and the locating hole. Although the diagram is omitted, the locating pin (locating hole) used to position the first terminal block 110 to the first housing 100 can also be of the same size as the locating pin 203 (locating hole 103).

[0037] Notes related to the techniques described in the examples. Figure 2The thick arrow X represents "the direction in which the second housing 200 approaches the first housing 100 when the second housing 200 is joined to the first housing 100". The locating pin 203, which determines the relative position of the first housing 100 and the second housing 200, extends along the thick arrow X. That is, "the direction in which the second housing 200 approaches the first housing 100 when the second housing 200 is joined to the first housing 100" can also be represented as "the direction in which the locating pin 203, which determines the relative position of the first housing 100 and the second housing 200, extends".

[0038] The first stroke L1 refers to the length of the portion of the first terminal 111 that is inserted into the first connector 210. The second stroke L2 is the same. The third stroke L3 refers to the length of the portion of the locating pin 203 that is inserted into the locating hole 103.

[0039] In the motor unit 10, a positioning pin 203 for positioning is provided on one of the first housing 100 and the second housing 200, and a positioning hole 103 for engaging the positioning pin 203 is provided on the other. The stroke of the positioning pin 203 (third stroke L3) can be longer than the first stroke L1.

[0040] "Resistance when inserting the first terminal 111 into the first connector 210" refers to the force generated between the first terminal 111 and the first connector 210 when the first terminal 111 is inserted into the first connector 210, which is the force generated in the direction opposite to the insertion direction. In other words, "resistance when inserting the first terminal 111 into the first connector 210" refers to the frictional force generated between the first terminal 111 and the first connector 210 when the first terminal 111 is inserted into the first connector 210. "Resistance when inserting the second terminal 121 into the second connector 220" has the same meaning.

[0041] The designations “first housing 100” / “second housing 200” are used to distinguish the names of the two housings that are being divided. The first housing 100 (second housing 200) can also be referred to as the second housing (first housing). The same applies to the designations “first terminal 111” and “second terminal 121”, and “first connector 210” and “second connector 220”.

[0042] In the motor unit 10, the first terminal 111 is connected to the first connector 210, and the second terminal 121 is connected to the second connector 220 simply through the opening 101 of the housing. The positioning pin 203, which positions the first housing 100 and the second housing 200, extends perpendicularly to the surface (opening surface) of the opening 101.

[0043] In the motor unit 10 of this embodiment, the first terminal 111 and the second terminal 121 are fixed to the first housing 100, and the first connector 210 and the second connector 220 are fixed to the second housing 200. Alternatively, the first terminal 111 and the second connector 220 may be fixed to the first housing 100, and the second terminal 121 and the first connector 210 may be fixed to the second housing 200. That is, the second terminal 121 may be fixed to one of the first housing 100 and the second housing 200, and the second connector 220 may be fixed to the other of the first housing 100 and the second housing 200. In other words, the second terminal 121 may be disposed in one of the first housing 100 and the second housing 200, and the second connector 220 may be disposed in the other of the first housing 100 and the second housing 200.

[0044] The electrical device in this embodiment is a motor unit 10 comprising a motor 130, an inverter 230, and a controller 240. The housing of the motor unit 10 is divided into a first housing 100 and a second housing 200. The motor 130 is housed in the first housing 100, and the inverter 230 that drives the motor 130 and the controller 240 that controls the inverter 230 are housed in the second housing 200. Alternatively, the motor 130 may be housed in the second housing 200, and the inverter 230 and controller 240 may be housed in the first housing 100. That is, the motor 130 may be housed in one of the first housing 100 and the second housing 200, and the inverter 230 and controller 240 may be housed in the other. A first terminal 111 and a first connector 210 connect a sensor 140 associated with the motor 130 and a controller 240. A second terminal 121 and a second connector 220 connect the motor 130 and the inverter 230.

[0045] The technology disclosed in this specification is not limited to the motor unit 10. The technology disclosed in this specification can be applied to all structures that include electrical components and housings that house and divide the electrical components. The first housing may also be referred to as a "housing body with an opening" and the second housing as a "housing cover with a closed opening". The first terminal and the first connector, and the second terminal and the second connector, electrically connect the electrical components in the first housing to the electrical components in the second housing.

[0046] The specific examples of the present invention have been described in detail above, but these are merely illustrative and do not limit the scope of the claims. The technology described in the claims includes technologies obtained by various modifications and alterations to the specific examples described above. The technical elements illustrated in this specification or drawings exert their technical usefulness individually or in various combinations, and are not limited to the combinations described in the claims at the time of application. Furthermore, the technology illustrated in this specification or drawings can achieve multiple objectives simultaneously, and achieving one of these objectives is itself technically useful.

Claims

1. An electrical device comprising: The first housing has an opening; The second housing is combined with the first housing to close the opening; A first terminal is disposed on the first housing and extends along the approach direction of the second housing toward the first housing when the second housing is joined to the first housing; A first connector is disposed in the second housing and is coupled to the first terminal; The second terminal is disposed on one of the first housing and the second housing, and extends parallel to the first terminal; and A second connector, disposed on the other side of the first housing and the second housing, is coupled to the second terminal. The length of the first terminal inserted into the first connector, i.e., the first stroke, is longer than the length of the second terminal inserted into the second connector, i.e., the second stroke.

2. The electrical equipment according to claim 1, wherein, The resistance when inserting the first terminal into the first connector is less than the resistance when inserting the second terminal into the second connector.

3. The electrical equipment according to claim 1 or 2, wherein, An electric motor is housed in one of the first and second housings, and an inverter for driving the electric motor and a controller for controlling the inverter are housed in the other of the first and second housings. The first terminal and the first connector will connect to the sensors associated with the motor and the controller. The second terminal and the second connector connect the motor and the inverter.

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