Driving device

Abstract

To provide a driving device capable of releasing heat generated in an electronic component.SOLUTION: A driving device 1 includes a motor 10 and an ECU 50. The motor 10 includes a motor housing 15, a stator 12 fixed on the motor housing, a motor line 11 wound around the stator, a rotor 13 configured to rotate by electric conduction to the motor line 11, and a shaft 14 that is rotatably supported by the motor housing 15 and rotates integrally with the rotor 13. The motor housing 15 includes a tubular motor case 16. The ECU 50 includes a substrate 53 on which electronic components involved in the driving control of the motor 10 are mounted, and an ECU housing 601 that accommodates the substrate 53, and is fixed on one side in an axial direction of the motor case 16. At least a part of the electronic components is embedded in the ECU housing 601.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a drive device. [Background technology]

[0002] Conventionally, there is known an electromechanically integrated motor in which a control device is integrally configured on one side of the motor in the axial direction. For example, in Patent Document 1, a heat sink is fixed to the inside of the motor housing by an interference fit. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2020-188556 A Summary of the Invention [Problem to be solved by the invention]

[0004] When heat from a heat generating element is dissipated to a heat sink, the heat is stored in the heat sink and transferred to the motor case, where the heat is dissipated into the space. In Patent Document 1, the heat sink and motor case, which serve as the heat dissipation path, are made of metal with good thermal conductivity. Here, for example, if the heat sink or other components that serve as the heat dissipation path are made of a material other than metal (e.g., resin), there is a risk that the heat dissipation will not be able to keep up with the amount of heat generated. Also, if the heat sink is provided inside the motor case, the heat generating components can only be placed in a location that faces the heat sink.

[0005] The present invention has been made in consideration of the above-mentioned problems, and has an object to provide a drive device capable of dissipating heat generated in electronic components. [Means for solving the problem]

[0006] A drive device (1) of the present invention includes a motor (10) and a controller (50). The motor has a housing (15) having a cylindrical motor case (16), a stator (12) fixed to the motor housing, a motor wire (11) wound around the stator, a rotor (13) that rotates when electricity is applied to the motor wire, and a shaft (14) that rotates integrally with the rotor.

[0007] The controller has a board (53) on which electronic components (54, 55) related to the drive control of the motor are mounted, and a controller housing (601-610) that houses the board, and is fixed to one axial side of the motor case. At least a portion of the electronic components is sealed in a state embedded in the controller housing made of an insulating material. By embedding the electronic components in the controller housing, heat from the electronic components can be dissipated to the controller housing. [Brief description of the drawings]

[0008] [Figure 1] 1 is a schematic configuration diagram of a steering system according to a first embodiment. [Diagram 2] FIG. 2 is a cross-sectional view of the drive device according to the first embodiment. [Diagram 3] 2 is a schematic diagram illustrating a connection between a motor case and an ECU case according to the first embodiment. FIG. [Figure 4] 4 is a flowchart illustrating an assembly process of the drive device according to the first embodiment. [Diagram 5] FIG. 2 is an explanatory diagram illustrating assembly of a motor case and a stator according to the first embodiment. [Figure 6] FIG. 4 is an explanatory diagram for explaining assembly of the rotor ASSY according to the first embodiment. [Figure 7] FIG. 2 is an explanatory diagram for explaining assembly of the motor ASSY according to the first embodiment. [Figure 8] 3 is an explanatory diagram for explaining assembly of an ECU case and an ECU-ASSY to a motor ASSY according to the first embodiment. FIG. [Figure 9]FIG. 11 is a cross-sectional view of a drive device according to a second embodiment. [Figure 10] FIG. 11 is a cross-sectional view of a drive device according to a third embodiment. [Figure 11] FIG. 11 is a cross-sectional view of a drive device according to a fourth embodiment. [Figure 12] 13 is a flowchart illustrating an assembly process of the drive device according to the fourth embodiment. [Figure 13] FIG. 13 is a cross-sectional view of a drive device according to a fifth embodiment. [Figure 14] FIG. 13 is an explanatory diagram for explaining assembly of an ECU case to a motor ASSY according to a fifth embodiment. [Figure 15] FIG. 13 is an explanatory diagram for explaining assembly of an ECU-ASSY into an ECU case according to a fifth embodiment. [Figure 16] FIG. 13 is a cross-sectional view of a drive device according to a sixth embodiment. [Figure 17] FIG. 13 is a cross-sectional view of a drive device according to a seventh embodiment. [Figure 18] FIG. 13 is a cross-sectional view of a drive device according to an eighth embodiment. [Figure 19] FIG. 13 is a cross-sectional view of a drive device according to a ninth embodiment. [Figure 20] FIG. 23 is a cross-sectional view of a drive device according to a tenth embodiment. [Figure 21] 23 is a flowchart illustrating an assembly process of the drive device according to the tenth embodiment. [Figure 22] FIG. 23 is an explanatory diagram for explaining the assembly of a motor ASSY and an ECU-ASSY according to a tenth embodiment. [Figure 23] FIG. 19 is a cross-sectional view of a drive device according to an eleventh embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A driving device according to the present invention will be described below with reference to the drawings. In the following, in a number of embodiments, substantially the same components are designated by the same reference numerals, and description thereof will be omitted.

[0010] (First embodiment) The first embodiment is shown in Fig. 1 to Fig. 8. As shown in Fig. 1, a drive device 1 includes a motor 10 and an ECU 50 serving as a controller, and is applied to an electric power steering device 8. Fig. 1 shows the configuration of a steering system 90 including the electric power steering device 8. The steering system 90 includes a steering wheel 91, which is a steering member, a steering shaft 92, a pinion gear 96, a rack shaft 97, wheels 98, the electric power steering device 8, and the like.

[0011] The steering wheel 91 is connected to a steering shaft 92. A torque sensor 94 that detects steering torque is provided on the steering shaft 92. A pinion gear 96 is provided on the tip of the steering shaft 92. The pinion gear 96 meshes with a rack shaft 97. A pair of wheels 98 are connected to both ends of the rack shaft 97 via tie rods or the like.

[0012] When a driver turns a steering wheel 91, a steering shaft 92 connected to the steering wheel 91 rotates. The rotational motion of the steering shaft 92 is converted into linear motion of a rack shaft 97 by a pinion gear 96. A pair of wheels 98 are steered to an angle according to the amount of displacement of the rack shaft 97.

[0013] The electric power steering device 8 includes a drive unit 1, and a reduction gear 89 which is a power transmission unit that reduces the speed of rotation of the motor 10 and transmits the reduced speed to a steering shaft 92. That is, the electric power steering device 8 of this embodiment is a so-called "column assist type", and the steering shaft 92 can be said to be the driven object. It may also be a so-called "rack assist type" in which the rotation of the motor 10 is transmitted to a rack shaft 97.

[0014] The motor 10 is, for example, a three-phase brushless motor. The motor 10 outputs a part or all of the torque required for steering, and is driven by power supplied from a battery (not shown) to rotate the reduction gear 89 forward and reverse. The drive device 1 is a so-called "mechatronically integrated type" in which the ECU 50 is provided on one side of the motor 10 in the axial direction. The mechatronically integrated type allows the motor 10 and the ECU 50 to be efficiently arranged in a vehicle with limited mounting space. Hereinafter, when the terms "axial direction" and "radial direction" are simply used, they will mean the axial direction and radial direction of the motor 10. Also, the lower side of the paper in FIG. 2 and the like is the output end side.

[0015] As shown in Fig. 2, 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 a motor wire 11 is wound around the stator 12. The motor wire 11 is not shown in any figures other than Fig. 2. The rotor 13 is provided radially inside the stator 12 and is provided to be rotatable relative to the stator 12.

[0016] The shaft 14 is fitted into the rotor 13 and rotates integrally with the rotor 13. The shaft 14 is rotatably supported in the motor housing 15 by bearings 141 and 142. The end of the shaft 14 on the ECU 50 side is exposed from the motor housing 15 to the ECU 50 side, and is provided with a sensor magnet 145. The end of the shaft 14 opposite the ECU 50 is an output end, which is provided with a pulley 147 and connected to the reduction gear 89.

[0017] The motor housing 15 has a motor case 16, a front frame 17, and a rear frame 18. The motor case 16 is formed into a cylindrical shape from, for example, aluminum. The motor case 16 has a front frame 17 integrally molded on the output end side, and an ECU case 61 (described later) integrally molded on the ECU 50 side. In this specification, the state in which at least one preformed member A is inserted to form a member B is referred to as "integrally molded" or "formed as an integrally molded product," and members A and B may be made of the same material or different materials.

[0018] The front frame 17 is made of, for example, phenolic resin, and seals the end portion on the output end side of the motor case 16. The front frame 17 is formed with a bearing holding portion 171, an outer wall abutment portion 172, a flange portion 175, and the like. The bearing holding portion 171 is provided with a bearing 141.

[0019] The outer wall abutment portion 172 is formed in a cylindrical shape extending along the outer peripheral wall of the motor case 16 toward the ECU 50 side from the radially inner side. Providing the outer wall abutment portion 172 suppresses the intrusion of water droplets and the like into the inside of the device from the connection portion between the motor case 16 and the front frame 17. A plurality of flange portions 175 are formed protruding radially outward, and are attached to the gearbox by fixing members such as screws (not shown). They may also be attached to a housing other than the gearbox.

[0020] The rear frame 18 is formed into a substantially circular plate shape from, for example, phenolic resin, and is fixed to the ECU 50 side of the motor case 16. A bearing 142 is fixed to the rear frame 18. The frames 17, 18 hold the bearings 141, 142, and can also be regarded as bearing holding members.

[0021] The ECU 50 includes a board 53, a connector 57, and an ECU housing 601. The board 53 is formed to extend radially outward beyond a motor area, which is an area obtained by projecting the motor case 16 in the axial direction, and is fixed to the ECU housing 601 by a fixing member 59 such as a tapping screw. A fixing member other than a tapping screw may be used, and the board 53 may be fixed to the ECU housing 601 by, for example, resin caulking. Hereinafter, the surface of the board 53 facing the motor 10 is referred to as a motor surface 531, and the surface opposite the motor 10 is referred to as a cover surface 532.

[0022] Lead wires 115 taken out from each phase of the motor wire 11 are formed to extend toward the ECU 50 and are electrically connected to the substrate 53 within the motor area. In this embodiment, the lead wires 115 are soldered to the substrate 53, but the connection method is not limited to soldering as long as an electrical connection is established, and may be, for example, an elastic connection by press-fit or a solderless connection such as a fitting connection using a socket connector.

[0023] 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 a cover surface 532 of the substrate 53. The heating element 54 includes a switching element constituting an inverter that switches the current supply to the motor wires 11, a motor relay, a power relay, and the like. The rotation angle sensor 56 is mounted on the motor surface 531 at a position facing the sensor magnet 145, and detects the rotation of the motor 10 by detecting the rotating magnetic field of the sensor magnet 145. Note that the rotation angle sensor 56 is not shown in the description of the assembly, etc.

[0024] Connector 57 is provided on the motor surface 531 side of substrate 53 outside the motor area, and connector terminal 571 is connected to substrate 53. A flange 575 extending from the main body to the outer periphery is formed on the end of connector 57 on the substrate 53 side. Flange 575 is formed in an L-shape in cross section so that its tip projects toward the opposite side to substrate 53.

[0025] The ECU housing 60 has an ECU case 61 and an ECU cover 71, and is formed to extend radially outward from the motor area. The ECU case 61 is formed, for example, from epoxy resin into a generally cylindrical shape with a bottom that opens on the side opposite the motor 10, and is integrally molded with the motor case 16, sealing the end of the motor case 16 on the ECU 50 side.

[0026] 3, the motor case 16 is formed with a sealing hole 162 penetrating in the plate thickness direction. A plurality of sealing holes 162 are formed at locations integrally molded with the ECU case 61, spaced apart in the circumferential direction. When the motor case 16 and the ECU case 61 are integrally molded, the ECU case 61 is formed at the end of the motor case 16 on the ECU 50 side, sandwiching the radially inner and outer sides. Here, the resin of the ECU case 61 enters the sealing hole 162, thereby improving the joining strength.

[0027] Similarly, a plurality of sealing holes 163 penetrating in the plate thickness direction are formed at intervals in the circumferential direction at the portion of the motor case 16 that is integrally molded with the front frame 17. When the motor case 16 and the front frame 17 are integrally molded, the resin of the front frame 17 penetrates into the sealing holes 163, thereby improving the joining strength.

[0028] Returning to FIG. 2, the ECU case 61 is formed with an outer wall abutment portion 611, a through hole 612, a board holding portion 613, a connector attachment portion 614, and a connector insertion hole 615 (see FIG. 8), etc.

[0029] The outer wall abutment portion 611 is formed in a cylindrical shape extending along the outer peripheral wall of the motor case 16 toward the output end side from the radially inner side. By providing the outer wall abutment portion 611, intrusion of water droplets and the like into the inside of the device from the connection portion between the motor case 16 and the ECU case 61 is suppressed. Note that the outer wall abutment portion 611 may not be provided, and the axial length of the radially outer portion of the motor case 16 at the connection portion between the motor case 16 and the ECU case 61 may be equal to or less than the axial length of the radially inner portion. The same applies to the outer wall abutment portion 172 of the front frame 17. Also, the illustration of the outer wall abutment portion 611 has been omitted as appropriate except in FIG. 2.

[0030] The through hole 612 is provided so as to penetrate in the axial direction at a position corresponding to the shaft 14, and the sensor magnet 145 is disposed inside. The board holding portion 613 is formed in the motor area, and the board 53 is fixed thereto by a fixing member 59. The connector 57 is attached to the connector attachment portion 614 by adhesive or the like. In detail, the main body portion of the connector 57 is inserted into the connector insertion hole 615 with the opening exposed to the outside, and then the flange portion 575 is inserted into the connector attachment portion 614 to which adhesive or the like is applied, thereby attaching the connector 57 to the ECU case 61.

[0031] The ECU cover 71 is made of, for example, epoxy resin, and is provided on the cover surface 532 side of the substrate 53. The ECU cover 71 is molded integrally with the ECU case 61, and resin-seals the substrate 53, and the heat generating element 54 and the capacitor 55 mounted on the cover surface 532 side of the substrate 53. The ECU cover 71 is formed with heat dissipation fins 711 in an element mounting area, which is an area obtained by projecting the area where the heat generating element 54 is mounted in the axial direction.

[0032] The assembly process of the drive device 1 of this embodiment will be described with reference to the flow chart of Fig. 4 and Fig. 5 to Fig. 8. Hereinafter, the "step" such as step S10 will be omitted, and the steps will simply be referred to as "S".

[0033] As shown in Fig. 5, in S10, the front frame 17 is integrally molded with the motor case 16. In S11, the stator 12 is shrink-fitted to the motor case 16. As shown in Fig. 6, in S12, the bearing 142 is fixed to the rear frame 18 by crimping, press-fitting, or the like. In S13, the bearings 141, 142 are press-fitted into the rotor assembly in which the shaft 14 is press-fitted into the rotor 13. Note that the order of S10, S11 and S12, S13 may be reversed, or they may be performed in parallel.

[0034] As shown in Fig. 7, in S14, the rotor ASSY in the state shown on the right side of Fig. 6 is assembled to the motor case 16 in the state shown on the right side of Fig. 5. Specifically, the rear frame 18 is shrink-fitted to the motor case 16. The bearing 141 is inserted into the bearing holder 171 of the front frame 17. In S15, the pulley 147 is press-fitted into the end of the shaft 14 on the output end side, and the sensor magnet 145 is press-fitted into the end of the shaft 14 on the ECU 50 side. Hereinafter, the state in which the stator 12, the front frame 17, the rear frame 18, etc. are assembled to the motor case 16 is referred to as the motor ASSY.

[0035] 8, in S16, in the state of the motor assembly, the ECU case 61 is molded integrally with the motor case 16 by resin (see the left side of FIG. 8). In S17, adhesive is applied to the connector attachment portion 614 of the ECU case 61. In S18, the ECU-ASSY with the connector 57 attached is attached to the ECU case 61 (see the right side of FIG. 8).

[0036] In S19, the lead wires 115 are electrically connected to the substrate 53. If the connection between the lead wires 115 and the substrate 53 is a solderless connection such as a press-fit connection, the connection is completed when the ECU-ASSY is attached to the ECU case 61 in S18, and S19 is omitted. In S20, the ECU-ASSY is sealed with resin, and the ECU cover 71 is formed (see FIG. 2). In the drawings, the rotor ASSY is designated as "RA", the motor ASSY as "MA", and the ECU ASSY as "EA" as appropriate.

[0037] For example, as a comparative example, if the rear frame were a metal heat sink and the heat from the heating element 54 was to be dissipated to the motor case 16 side, the heating element 54 had to be mounted on the motor surface 531 side of the substrate 53 and within the motor area.

[0038] In contrast, in the drive unit 1 of this embodiment, the heat generating element 54 is embedded in resin in the ECU cover 71, and heat is dissipated by air radiation through the ECU cover 71 with which the heat generating element 54 is in direct contact. This makes it possible to mount the heat generating element 54 on the cover surface 532 side or outside the motor area, improving the freedom of board design. Also, there is no need for an intermediate material such as heat dissipation gel that is required when dissipating heat to a metal heat sink.

[0039] The ECU case 61 is molded integrally with the motor case 16 by insert molding, and seals the end of the motor case 16. The front frame 17 is molded integrally with the motor case 16 by insert molding, and seals the end of the motor case 16. This makes it possible to prevent water droplets, dust, etc. from entering the inside of the device with a simple configuration without any gap corrosion. In addition, since the ECU case 61 and the front frame 17 are sealed without using a sealant such as an adhesive to connect the motor case 16, no gaps are created due to deterioration of the sealant over time, and waterproof performance can be maintained over time. It is preferable that the ECU case 61 and the front frame 17, which are molded integrally, and the motor case 16 are made of materials with similar linear expansion coefficients.

[0040] In this embodiment, the motor case 16 is made of metal, and the front frame 17 is made of resin. In other words, in this embodiment, instead of forming the motor case as a cylindrical shape with a bottom and the cylindrical part and the side opposite to the ECU 50 as one member, the cylindrical motor case 16 and the approximately disk-shaped front frame 17 are separated, and the end of the metal motor case 16 is molded with resin to form the front frame 17, so that the motor case 16 and the front frame 17 are molded as one piece. This allows the members to be separated without deteriorating corrosion resistance. Note that since the front frame 17 is relatively easy to form by making it a separate member from the motor case 16, it is also possible to use a material that has good corrosion resistance and relatively low fluidity.

[0041] As described above, the drive device 1 includes the motor 10 and the ECU 50. The motor 10 includes a motor housing 15 having a cylindrical motor case 16, a stator 12 fixed to the motor housing 15, a motor wire 11 wound around the stator, a rotor 13 that rotates when electricity is applied to the motor wire 11, and a shaft 14 that is rotatably supported by the motor housing 15 and rotates integrally with the rotor 13.

[0042] The ECU 50 has a board 53 on which electronic components related to drive control of the motor 10 are mounted, and an ECU housing 601 that houses the board 53, and is fixed to one axial side of the motor case 16. The electronic components include a heating element 54 and a capacitor 55. At least a portion of the electronic components are sealed in a state embedded in the ECU housing 601 formed of an insulating material.

[0043] In this embodiment, the electronic components are embedded in the ECU housing 601 with resin, so that heat generated by current flow to the electronic components can be dissipated from the ECU housing 601. Also, dissipating heat from the ECU housing 601 allows components that require heat dissipation to be arranged outside the motor area, and provides greater freedom in board design compared to dissipating heat to the motor side, such as the rear frame 18. Furthermore, forming the ECU housing 601 from an insulating material such as resin eliminates the need for an intermediate material such as heat dissipation gel that is required when dissipating heat to a heat sink or the like made of a metal material.

[0044] The ECU housing 601 has an ECU case 61 fixed to the motor case 16, and an ECU cover 71 sealing electronic components mounted on a cover surface 532, which is the surface of the board 53 opposite to the motor 10. This allows heat from the electronic components mounted on the cover surface 532 to be dissipated to the ECU cover 71.

[0045] The ECU case 61 seals the end of the motor case 16 on the ECU 50 side. In this embodiment, the ECU case 61 sandwiches the radially inner and outer sides of the motor case 16 and is molded integrally with the motor case 16. This allows the ECU 50 to be assembled to the motor case 16 without using adhesives or the like, making it possible to prevent water droplets and foreign matter from entering the inside of the device through the connection points between the motor 10 and the ECU 50.

[0046] The electronic components include a heating element 54 that generates heat when energized. Heat dissipation fins 711 are formed on the ECU cover 71 of the ECU housing 601 at locations where the heating element 54 is projected in the axial direction. This makes it possible to improve the heat dissipation efficiency of the heating element 54.

[0047] Second embodiment The second embodiment is shown in Fig. 9. The second to eleventh embodiments differ from the above-mentioned embodiments mainly in the ECU housing, and this point will be mainly described. An ECU housing 602 according to the second embodiment has an ECU case 62 and an ECU cover 71. The ECU case 62 is formed with heat dissipation fins 621.

[0048] In this embodiment, the heat generating element 54 is mounted on the motor surface 531 and the cover surface 532. When appropriately distinguishing between the mounting surfaces below, the heat generating element mounted on the motor surface 531 will be referred to as a motor-side element 541, and the heat generating element mounted on the cover surface 532 will be referred to as a cover-side element 542. The motor-side element 541 abuts against the ECU case 62, and dissipates heat to the ECU case 62 side. A heat dissipation gel or the like may be provided between the motor-side element 541 and the ECU case 62.

[0049] The motor side element 541 is mounted outside the motor area of ​​the substrate 53. The heat dissipation fins 621 are formed in the element mounting area where the motor side element 541 is mounted. By disposing the motor side element 541 outside the motor area, a configuration for improving the heat dissipation efficiency of the heat dissipation fins 621 and the like can be provided in the ECU case 62 without interfering with the motor case 16. In addition, the same effects as those of the above embodiment are achieved.

[0050] Third embodiment The third embodiment is shown in Fig. 10. An ECU housing 603 of this embodiment has an ECU case 63 and an ECU cover 72. The ECU case 63 is integrally molded with the motor case 16 so as to be generally contained within the motor area. Although an outer wall abutment portion is omitted in Fig. 10, an outer wall abutment portion may be provided. The same applies to the embodiments described below.

[0051] The ECU cover 72 is formed to extend radially outwardly to the outside of the motor region, and integrally seals both sides of the substrate 53 with resin. On the motor surface 531 side, the ECU cover 72 seals the radially outer region of the through-hole 612 of the ECU case 63. That is, the rotation angle sensor 56 mounted inside the through-hole 612 of the motor surface 531 is not sealed in the ECU cover 72, and faces the sensor magnet 145 in an exposed state. The ECU cover 72 has heat dissipation fins 721, 722 formed in an element mounting region where the heat generating element 54 is mounted.

[0052] In this embodiment, the ECU case 63 is molded integrally with the motor ASSY (S16 in FIG. 4), the ECU-ASSY with the connector 57 assembled thereto is assembled to the ECU case 63 (S18), and the board 53 and the lead wires 115 are electrically connected (S19). Then, the motor surface 531 side and the cover surface 532 side of the board 53 are sealed with resin to form the ECU cover 72 (S20).

[0053] The ECU cover 72 of this embodiment integrally seals not only the elements mounted on the cover surface 532 side of the substrate 53, but also the connector 57 and the motor side elements 541 provided on the motor surface 531 side. This allows the motor side elements 541 to be embedded in the ECU cover 72 with resin, allowing heat to be dissipated to the ECU cover 72. Also, the step (S17) of connecting the connector 57 and the ECU case with an adhesive is not required. When the connector 57 is integrally molded with the ECU housing, the flange 575 may be omitted.

[0054] A through hole 612 is formed in the ECU case 63, in which the end of the shaft 14 on the ECU 50 side is disposed. The ECU cover 72 seals the electronic components mounted on the motor surface 531, which is the surface on the motor side of the board 53, outside the through hole 612. This allows the electronic components mounted on the motor surface 531 to be embedded in the ECU cover 72 with resin and dissipate heat. This also provides the same effects as the above embodiment.

[0055] (Fourth embodiment) The fourth embodiment is shown in Figures 11 and 12. In the ECU housing 604 of this embodiment, both sides of the motor case 16 and the substrate 53 are integrally sealed with resin. In other words, the ECU housing 604 of this embodiment can be considered as the ECU case and ECU cover of the above-mentioned embodiments being formed from a single member. The ECU housing 604 has a sensor magnet 145 disposed therein and an opening 618 that opens to the motor 10 side. The rotation angle sensor 56 is mounted on the motor surface 531 of the substrate 53 at a location exposed from the opening 618 and facing the sensor magnet 145.

[0056] The motor housing 150 has a motor case 16, a front frame 17, and a rear frame 19. The rear frame 19 is formed with a plurality of board holding portions 191 formed to protrude toward the ECU 50. The board 53 is fixed to the board holding portions 191 by the fixing member 59, resin rivets, or the like.

[0057] The assembly process of this embodiment will be described with reference to the flowchart of Fig. 12. The assembly of the motor assembly in S10 to S15 is the same as that in Fig. 4. In S21, which follows S15, the board 53 is attached to the board holder 191, and the ECU-ASSY is assembled to the motor assembly. In S22, similar to S19 in Fig. 4, the board 53 and the lead wires 115 are electrically connected. In S23, the motor case 16 and the ECU-ASSY are integrally sealed with resin to form the ECU housing 604.

[0058] In this embodiment, the motor housing 150 has a rear frame 19 that is fixed to the motor case 16 on the ECU 50 side of the stator 12 and has a board holding portion 191 that protrudes toward the ECU 50 side and holds the board 53. The ECU housing 604 integrally seals the end of the motor case 16 on the ECU 50 side and both sides of the board 53. This makes it possible to reduce the number of parts. Also, it makes it possible to reduce the number of places that require adhesion using an adhesive or the like. Also, the same effects as the above embodiment are achieved.

[0059] (Fifth and Sixth Embodiments) The fifth embodiment is shown in Fig. 13 to Fig. 15, and the sixth embodiment is shown in Fig. 16. As shown in Fig. 13, in the fifth embodiment, an ECU housing 605 has an ECU case 64 and an ECU cover 73.

[0060] The ECU case 64 has an adhesive groove 641 into which the end of the motor case 16 on the ECU 50 side is inserted, and is formed of a resin such as PBT separately from the motor case 16. The motor case 16 of this embodiment is not provided with a sealing hole 162. The ECU case 64 is attached to the motor case 16 by an adhesive applied to the adhesive groove 641. The ECU case 64 is formed to extend to the outside of the motor area, and has heat dissipation fins 621 formed thereon.

[0061] The ECU cover 73 is integrally molded with the ECU case 64, and resin-seals the electronic components mounted on the cover surface 532 of the substrate 53 and the electronic components mounted outside the through-hole 612 of the motor surface 531. The ECU cover 73 is formed with heat dissipation fins 711.

[0062] 16, in the sixth embodiment, an ECU housing 606 has an ECU case 65 and an ECU cover 72. The ECU case 65 is separate from the motor case 16 and is formed generally in the motor area. The ECU case 65 is similar to the ECU case 63 of the third embodiment, except that it is attached to the motor case 16 by adhesive.

[0063] The assembly process of the drive unit 1 will be described using the fifth embodiment as an example. The assembly flow is the same as that of the first embodiment, except that in assembling the motor ASSY and the ECU case in S16 of Fig. 4, the motor case 16 and the ECU case 64 are fixed with an adhesive instead of being integrally molded.

[0064] 14, adhesive is applied to the adhesive groove 641 of the ECU case 64, and the end of the motor case 16 on the ECU 50 side is inserted into the adhesive groove 641. In this way, the ECU case 64 is assembled to the motor ASSY.

[0065] 15, adhesive is applied to connector mounting portion 614 of ECU case 64, and ECU-ASSY is assembled to ECU case 64. Then, after lead wires 115 and substrate 53 are electrically connected, ECU-ASSY is sealed with resin to form ECU cover 73 (see FIG. 13).

[0066] By making the ECU cases 64, 65 separate from the motor case 16, the ECU-ASSY can be relatively easily assembled to the motor ASSY. Also, the ECU cases 64, 65 can be easily formed. Also, the same effects as those of the above embodiment can be achieved.

[0067] (Seventh and eighth embodiments) The seventh embodiment is shown in FIG. 17, and the eighth embodiment is shown in FIG. 18. As shown in FIG. 17, an ECU housing 607 of the seventh embodiment has an ECU case 62 and an ECU cover 74. The ECU cover 74 is substantially the same as the ECU cover 71 of the first embodiment, except that no heat dissipation fins are formed. On the surface of the ECU cover 74 opposite to the motor 10, a cover member 741 is attached to an element mounting area where the heat generating element 54 is mounted. In this embodiment, the cover member 741 is attached later with an adhesive or the like after the ECU cover 74 is integrally molded with the ECU case 62. Also, as in the eighth embodiment shown in FIG. 18, a plate-shaped cover member 742 may be insert-molded into the ECU cover 74 in the element mounting area.

[0068] The cover members 741 and 742 are formed of a metal such as an iron plate having good thermal conductivity, but may be made of resin. By providing the cover members 741 and 742, it is possible to improve the heat dissipation efficiency of the heating element 54. In addition, the cover members 741 and 742 also function as reinforcement for the ECU cover 74.

[0069] In this embodiment, the ECU cover 74 of the ECU housing 607 is provided with cover members 741 and 742 at positions where the electronic components are projected in the axial direction. This makes it possible to protect the electronic components from external forces. In addition, by forming the cover members 741 and 742 from a material with good thermal conductivity, a thermal mass is added, making it possible to improve the heat dissipation efficiency. In addition, the same effects as those of the above embodiment are achieved.

[0070] Ninth embodiment The ninth embodiment is shown in Fig. 19. As shown in Fig. 19, an ECU housing 608 has an ECU case 62 and an ECU cover 75. A flow path 751 through which a fluid such as coolant can flow is formed in the ECU cover 75 at a location where the heat generating element 54 is projected in the axial direction. This can improve the heat dissipation efficiency of the heat generating element 54. In addition, the same effects as those of the above embodiments are achieved. The cover members 741, 742 and the flow path 751 of the seventh to ninth embodiments may be provided in the ECU housing according to any of the embodiments.

[0071] Tenth embodiment The tenth embodiment is shown in Fig. 20 to Fig. 22. As shown in Fig. 20, an ECU housing 609 has an ECU case 66 and an ECU cover 76. An adhesive groove 641 is formed in the ECU case 66, and the ECU case 66 is fixed to the motor case 16 with an adhesive. A lead wire insertion hole 661 is formed in the ECU case 66.

[0072] The ECU cover 76 is molded integrally with the ECU case 66. A communication hole 761 is formed in the ECU cover 76, which communicates the connection portion between the lead wire 115 and the substrate 53 with the outside. A jig used for connecting the substrate 53 and the lead wire 115 can be inserted through the communication hole 761. The opening of the communication hole 761 is sealed with a sealing cover 765. The adhesive portion of the sealing cover 765 is inserted into the adhesive groove 762, and is attached to the ECU cover 76 with an adhesive.

[0073] The assembly process of the drive unit 1 of this embodiment will now be described with reference to the flowchart of Fig. 21 and Fig. 22. As shown on the left side of Fig. 22, in S31, the ECU-ASSY is integrally molded. In detail, the ECU case 66 and the ECU cover 76 are integrally molded, and the motor surface 531 side and the cover surface 532 side of the substrate 53 are sealed with resin. In S32, an adhesive is applied to the adhesive grooves 641.

[0074] 22, in S33, the resin-sealed ECU-ASSY is assembled to the motor ASSY. That is, in this embodiment, the ECU-ASSY is formed separately from the motor ASSY and assembled. The assembly process of the motor ASSY is the same as that of the first embodiment, so the description will be omitted.

[0075] In S34, lead wire 115 is electrically connected to substrate 53. In this embodiment, since communication hole 761 is provided, a tool can be inserted through the communication hole and lead wire 115 can be connected to substrate 53 by soldering or the like. In S35, sealing cover 755 is attached to close the opening of communication hole 761 (see FIG. 20).

[0076] The ECU cover 76 of the ECU housing 609 has a communication hole 761 that communicates between the connection point between the substrate 53 and the motor wire 11 and the outside. The opening of the communication hole 761 is sealed with a sealing cover 765. By providing the communication hole 761 in the ECU cover 76, the ECU-ASSY can be assembled to the motor ASSY in a resin-sealed state. This makes it relatively easy to seal the ECU-ASSY with resin. In addition, the same effects as those of the above embodiment are achieved.

[0077] Eleventh embodiment The eleventh embodiment is shown in Fig. 23. An ECU housing 610 has an ECU case 66 and an ECU cover 77. A terminal escape groove 771 is formed in the ECU cover 77. The terminal escape groove 771 is capable of receiving the tip of the lead wire 115 and is not open to the outside.

[0078] In this embodiment, the lead wire 115 and the substrate 53 are electrically connected by a solderless connection without using solder. In this embodiment, a press-fit portion 116 is formed at the tip of the lead wire 115, and the lead wire 115 and the substrate 53 are connected by elastic contact. The connection between the lead wire 115 and the substrate 53 is not limited to press-fit, and may be made using, for example, a socket connector, etc., as long as the electrical connection can be made without soldering. In other words, a "solderless connection" that does not involve soldering includes a "connection by elastic contact" such as a press-fit connection, and a "connection by fitting" using a socket connector, etc.

[0079] The assembly process is generally similar to that of the eleventh embodiment, but in this embodiment, the lead wires 115 and the substrate 53 are press-fit connected, so that the electrical connection between the motor ASSY and the ECU ASSY is completed at the stage of assembling the resin-sealed ECU ASSY to the motor ASSY in S33. Also, since there is no need to provide a communication hole and a sealing cover to seal it, the number of parts and the assembly process can be reduced.

[0080] In this embodiment, the motor wires 11 are electrically connected to the board 53 by a solderless connection. A terminal escape groove 771 is formed in the ECU cover 77 of the ECU housing 610 at a location corresponding to the connection between the lead wires 115 and the board 53. By configuring the motor wires 11 and the board 53 to be electrically connected without soldering, it is possible to omit the soldering process after assembling the ECU-ASSY to the motor ASSY. In addition, the same effects as those of the above embodiment are achieved.

[0081] In the embodiment, rear frame 19 corresponds to the "frame member", ECU 50 corresponds to the "controller", ECU housings 601-610 correspond to the "controller housing", ECU cases 61-66 correspond to the "first housing", ECU covers 71-77 correspond to the "second housing", heat generating element 54 and capacitor 55 correspond to the "electronic component", heat generating element 54 corresponds to the "heat generating component", and sensor magnet 154 corresponds to the "detected member".

[0082] (Other embodiments) In the above embodiment, an example was shown in which the front frame and rear frame are mainly made of phenolic resin, and the controller housing is mainly made of epoxy resin or PBT. In other embodiments, the controller housing may be made of materials other than epoxy resin or PBT. The front frame and rear frame may be made of materials other than phenolic resin. For example, the rear frame may be made of a metal with good thermal conductivity, such as an aluminum alloy, to further improve heat dissipation. The motor case may be made of resin instead of aluminum.

[0083] In the above embodiment, the motor case is formed such that the front frame and the motor case are integrally molded as separate members. In other embodiments, the motor case may be formed into a cylindrical shape with a bottom that opens toward the controller, and the motor case and the front frame may be formed into a single member. As a supplementary note, even when the motor case is formed into a cylindrical shape with a bottom, it is still included in the concept of a "cylindrical motor case."

[0084] In the above embodiment, when the motor case and the controller housing are integrally molded, a sealing hole is formed in the motor case, and the motor case is integrally molded with the controller housing sandwiching the radially inner and outer sides. In other embodiments, when the motor case and the ECU housing are integrally molded, the motor case does not have to be sandwiched between the radially inner and outer sides. Also, the sealing hole may be omitted. The same applies to the connection points between the motor case and the front frame.

[0085] In the above embodiment, the heat dissipation rib, the cover member, or the flow passage portion is provided in the axial projection area of ​​the heat generating component. In other embodiments, depending on the thermal mass of the controller housing, the heat dissipation rib, the cover member, the flow passage portion, or other configurations for improving heat dissipation may be omitted or may be provided in combination.

[0086] In the above embodiment, the connector is provided on the motor side of the board, with the opening facing the output end side in the axial direction. In other embodiments, the connector may be provided on the cover side of the board, or the opening may face in a different direction. Furthermore, multiple connectors may be provided. Also, the arrangement of elements on the board may be different from that of the above embodiment.

[0087] In the above embodiment, the controller is formed to extend radially outward beyond the motor region. In other embodiments, the controller may be provided within the motor region. In the above embodiment, the drive device is applied to an electric power steering device. In other embodiments, the drive device may be applied to an in-vehicle device other than an electric power steering device, or may be applied to a device other than an in-vehicle device.

[0088] It may also be that "the electronic components include a heat-generating component (54) that generates heat when current is applied, and the controller housing has at least one of a heat dissipation fin (621, 711, 721, 722) and a flow path portion (751) through which a fluid can flow, at a location where the heat-generating component is projected in the axial direction."

[0089] The driving device according to any one of Aspects 1 to 6 may be configured as follows: "The controller housing (607) is provided with cover members (741, 742) at locations where the electronic components are projected in the axial direction."

[0090] The drive device may be configured as described in any one of aspects 1 to 7, wherein the controller housing (609) has a communication hole (761) that connects the connection point between the board and the motor wire to the outside, and the opening of the communication hole is blocked by a sealing cover (765).

[0091] The drive device may be configured as described in any one of aspects 1 to 7, in which "the motor wire is electrically connected to the board by a solderless connection, and the controller housing (610) has a terminal escape groove (771) formed at a location corresponding to the connection between the motor wire and the board."

[0092] As described above, the present invention is not limited to the above-described embodiment, and can be embodied in various forms without departing from the spirit of the invention. [Explanation of symbols]

[0093] 1 Drive unit 10 Motor 11 Motor wire 12 stator 13 rotor 14 shaft 15, 150···Motor housing 16···Motor case 50 ECU (controller) 53 Circuit board 54 Heat generating elements (electronic components, heat generating components) 55 Capacitor (electronic component) 601~610···ECU housing (controller housing) 61~66···ECU case (first housing) 71~77···ECU cover (second housing)

Claims

1. a motor (10) having a motor housing (15, 150) with a cylindrical motor case (16), a stator (12) fixed to the motor housing, a motor wire (11) wound around the stator, a rotor (13) that rotates when current is applied to the motor wire, and a shaft (14) that rotates integrally with the rotor; a controller (50) having a board (53) on which electronic components (54, 55) relating to drive control of the motor are mounted and a controller housing (601-610) for accommodating the board, the controller being fixed to one side of the motor case in the axial direction; Equipped with A drive device in which at least a portion of the electronic components are embedded and sealed in the controller housing, which is made of an insulating material.

2. The drive device of claim 1, wherein the controller housing has a first housing (61-64, 66-68) fixed to the motor case, and a second housing (71-77) sealing the electronic components mounted on the surface of the board opposite the motor.

3. The first housing has a through hole (612) in which the end of the shaft on the controller side is disposed, The drive unit according to claim 2 , wherein the second housing seals the electronic components mounted on the motor side surface of the board outside the through hole.

4. 4. The drive device according to claim 2, wherein the first housing seals an end of the motor case on the controller side.

5. the motor housing (150) has a frame member (19) that is fixed to the motor case on the controller side of the stator and has a board holding portion (191) formed thereon that protrudes toward the controller and holds the board; 2. The drive device according to claim 1, wherein the controller housing integrally seals the end of the motor case on the controller side and both sides of the circuit board.

6. The electronic components include a heat generating component (54) that generates heat when current is applied, The drive device according to claim 1, wherein the controller housing is formed with at least one of a heat dissipation fin (621, 711, 721, 722) and a flow path portion (751) through which a fluid can flow, at a location where the heat-generating component is projected in the axial direction.

7. 2. The drive device according to claim 1, wherein cover members (741, 742) are provided on the controller housing (607) at locations where the electronic components are projected in the axial direction.

8. The controller housing (609) has a communication hole (761) that communicates a connection point between the board and the motor wire with the outside, The drive unit according to claim 1 , wherein the opening of the communication hole is closed by a sealing cover (765).

9. the motor wire is electrically connected to the board by a solderless connection, 2. The drive device according to claim 1, wherein the controller housing (610) is formed with a terminal escape groove (771) at a location corresponding to a connection portion between the motor wire and the board.

Images