Electric drive device

Abstract

To provide an electric drive device which is capable of easily changing an angle or a direction of a connector opening and applicable to electric power steering devices of different vehicle layouts.SOLUTION: An electric drive device 10 comprises: a housing 1 housing a circuit board 3 on which an electronic control device is loaded, and an electric motor 2; a connector block 4 to which connectors 4a, 4b, 4c and 4d are attached and which seals the housing; and a seal part which is interposed in a junction 5 between the housing and the connector block. The circuit board is disposed in a horizontal direction with respect to a rotation axis of the electric motor. The connector block includes: a first face f1 including a connector opening; a second face f2 connected to the first face at a predetermined angle; and a third face f3 and a fourth face f4 which are positioned at both sides with respect to a direction in which the first face and the second face are connected. An angle in the junction of the third face and the fourth face with the housing with respect to the first face and the second face is smaller than a predetermined angle.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an electric drive device in which an electric motor and a control device that controls the drive of the electric motor are integrated together, and is applied to, for example, an electric power steering device. [Background technology]

[0002] Patent Document 1 describes an electric power steering device that includes an electric motor that outputs auxiliary torque to the steering wheel of a vehicle, and a control device that drives and controls the electric motor. A board on which the control device is mounted is disposed parallel to the motor shaft and attached to the electric motor. A connector opening is provided on the underside of the board in a direction perpendicular to the motor shaft, and a seal structure is provided on the same surface (or horizontal surface) as the installation surface. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2007-137302 A Summary of the Invention [Problem to be solved by the invention]

[0004] In this type of control device, the orientation of the connector opening is usually determined in advance, and new products are developed by setting the orientation of the connector opening in accordance with the requirements of each vehicle in which the control device is to be installed.

[0005] For example, in the control device of Patent Document 1, the positional relationship between the connector opening and the seal part on the housing side is fixed, so the orientation of the connector opening cannot be changed relative to the position of the seal part. In addition, since the orientation of the connector opening is determined when the connector base is connected to the exterior part of the ECU (Electronic Control Unit), when the connector opening needs to be changed, the connector base needs to be redesigned and remade. Therefore, there is a problem that a great deal of development work is required to apply the control device to an electric power steering device with a different vehicle layout, which leads to an increase in product costs.

[0006] The present invention has been made in consideration of the above-mentioned circumstances, and its object is to provide an electric drive device that allows the angle and direction of the connector opening to be easily changed and can be applied to electric power steering devices with different vehicle layouts. [Means for solving the problem]

[0007] An electric drive device according to one aspect of the present invention comprises an electric motor having a plurality of independent winding sets, an electronic control device that controls the drive of the electric motor, a circuit board on which the electronic control device is mounted, a housing that accommodates the electric motor, a connector block to which external terminals are attached and that seals the housing, and a seal portion interposed at the joint between the housing and the connector block, wherein the circuit board is arranged horizontally with respect to the rotational axis of the electric motor, and the connector block has a first surface having a connector opening, a second surface connected to the first surface at a predetermined angle, and a third surface and a fourth surface located on both sides in the direction in which the first surface and the second surface are connected, and the angle between the first surface and the second surface at the joint between the third surface and the housing is smaller than the predetermined angle. Effect of the Invention

[0008] In the present invention, the first and second surfaces are set at a predetermined angle (e.g., 90 degrees), and the angle of the seal portions of the third and fourth surfaces with respect to the first and second surfaces is set at an angle (e.g., 45 degrees) smaller than the predetermined angle, thereby forming a seal portion with an inclined surface. This allows the connector block to be assembled by, for example, rotating it half a turn (180 degrees) and wiring the connector and the circuit board, so that the angle and direction of the connector opening can be easily changed and installed. With this configuration, when assembling the connector block, multiple options (two options) can be selected for the seal portion, allowing the electric drive device to be applied to electric power steering devices with different vehicle layouts and also allowing for design changes during development. Therefore, the angle and direction of the connector opening can be easily changed, making it possible to provide an electric drive device that can be applied to electric power steering devices with different vehicle layouts. [Brief description of the drawings]

[0009] [Figure 1] 1 is a perspective view showing a schematic configuration example of a first mode of an electric drive device according to a first embodiment of the present invention. [Diagram 2] 2 is a front view of the electric drive device shown in FIG. 1, from the opposite side to the motor output shaft. [Diagram 3] FIG. 2 is a side view of the electric drive device shown in FIG. [Figure 4] 2 is a cross-sectional view taken along line X1-X1' of the electric drive device shown in FIG. [Diagram 5] FIG. 2 is an exploded view of the electric drive device shown in FIG. [Figure 6] 2 is a perspective view showing an example of the configuration of a joint on a housing side in the electric drive device shown in FIG. 1. [Figure 7] 2 is a perspective view showing a configuration example of a joint portion on a connector block side in the electric drive device shown in FIG. 1. [Figure 8] 1 is a schematic configuration diagram of an electric power steering device to which an electric drive device according to an embodiment of the present invention is applied; [Figure 9]9 is a diagram illustrating an area near a mounting portion when the electric drive device of the first embodiment is applied to the electric power steering device shown in FIG. 8. FIG. [Figure 10] FIG. 4 is a perspective view showing a schematic configuration example of a second mode of the electric drive device according to the first embodiment of the present invention. [Figure 11] 11 is a front view of the electric drive device shown in FIG. 10 from the opposite side to the motor output shaft. [Figure 12] FIG. 11 is a side view of the electric drive device shown in FIG. [Figure 13] 11 is a cross-sectional view taken along line X2-X2' of the electric drive device shown in FIG. [Figure 14] 9 is a diagram illustrating an area near a mounting portion when the electric drive device of the second embodiment is applied to the electric power steering device shown in FIG. 8. FIG. [Figure 15] FIG. 11 is a perspective view showing a schematic configuration example of a first mode of an electric drive device according to a second embodiment of the present invention. [Figure 16] 16 is a front view of the electric drive device shown in FIG. 15, from the side opposite to the motor output shaft. [Figure 17] FIG. 16 is a side view of the electric drive device shown in FIG. [Figure 18] 16 is a cross-sectional view of the electric drive device shown in FIG. 15 taken along line X3-X3'. [Figure 19] FIG. 16 is an exploded view of the electric drive device shown in FIG. [Figure 20] FIG. 11 is a perspective view showing a schematic configuration example of a second form of an electric drive device according to a second embodiment of the present invention. [Figure 21] 21 is a front view of the electric drive device shown in FIG. 20 from the opposite side to the motor output shaft. [Figure 22] FIG. 21 is a side view of the electric drive device shown in FIG. 20. [Diagram 23] 21 is a cross-sectional view taken along line X4-X4' of the electric drive device shown in FIG. 20. [Figure 24] FIG. 11 is a perspective view showing a schematic configuration example of a first mode of an electric drive device according to a third embodiment of the present invention. [Diagram 25]FIG. 25 is a front view of the electric drive device shown in FIG. 24, from the opposite side to the motor output shaft. [Figure 26] FIG. 25 is a side view of the electric drive device shown in FIG. 24. [Figure 27] 25 is a cross-sectional view taken along line X5-X5' of the electric drive device shown in FIG. 24. [Figure 28] FIG. 25 is an exploded view of the electric drive device shown in FIG. 24. [Figure 29] FIG. 13 is a perspective view showing a schematic configuration example of a second mode of an electric drive device according to a third embodiment of the present invention. [Diagram 30] 30 is a front view of the electric drive device shown in FIG. 29 from the opposite side to the motor output shaft. [Diagram 31] FIG. 30 is a side view of the electric drive device shown in FIG. 29. [Diagram 32] 30 is a cross-sectional view taken along line X6-X6' of the electric drive device shown in FIG. 29. [Diagram 33] FIG. 13 is a perspective view showing a schematic configuration example of a first mode of an electric drive device according to a fourth embodiment of the present invention. [Diagram 34] FIG. 34 is a side view of the electric drive device shown in FIG. 33. [Diagram 35] 34 is a cross-sectional view taken along line X7-X7' of the electric drive device shown in FIG. 33. [Diagram 36] FIG. 34 is an exploded view of the electric drive device shown in FIG. 33. [Figure 37] FIG. 13 is a perspective view showing a schematic configuration example of a second mode of an electric drive device according to a fourth embodiment of the present invention. [Figure 38] FIG. 38 is a side view of the electric drive device shown in FIG. 37. [Figure 39] 38 is a cross-sectional view taken along line X8-X8' of the electric drive device shown in FIG. 37. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. [First embodiment] Fig. 1 to Fig. 5 respectively show a schematic configuration example of a first form of an electric drive device according to a first embodiment of the present invention, with Fig. 1 being a perspective view, Fig. 2 being a front view of the side opposite to the motor output shaft, Fig. 3 being a side view, Fig. 4 being a cross-sectional view taken along line X1-X1' in Fig. 1, and Fig. 5 being an exploded view. In the first form of this first embodiment, the connector opening of the connector block is located on the motor rotation shaft.

[0011] Housing 1 contains an electric motor 2 having multiple independent winding sets, and a circuit board 3 on which an electronic control unit (ECU) is mounted. As shown by the arrow AL in Fig. 5, the circuit board 3 is inserted into housing 1 from the direction of the rotating shaft 2a, and is accommodated on the internal upper surface of housing 1 of the electric motor 2. The component mounting surface of circuit board 3 is arranged horizontally with respect to the rotating shaft 2a of the electric motor 2. The electronic control unit is made up of electronic components and electronic circuits that control the drive of electric motor 2. Housing 1 is sealed by a connector block 4 installed on the opposite side to the motor output shaft 2b.

[0012] Power supply and communication connectors 4a, 4b and sensor connectors 4c, 4d (external terminals) are attached to the connector block 4. The openings of the connectors 4a, 4b, 4c, 4d are arranged in the direction of the motor rotation shaft 2a. In addition, a joint 5 between the housing 1 and the connector block 4 is inclined at a predetermined angle, for example, 45 degrees, with respect to the rotation shaft 2a of the electric motor 2.

[0013] The connector block 4 has a first surface (opening installation surface) f1 having an opening for the connectors 4a, 4b, 4c, and 4d, a second surface (vertical surface) f2 connected to the first surface f1 at a predetermined angle Δ1, for example, 90 degrees, and a third surface (side surface) f3 and a fourth surface (side surface) f4 located on both sides of the direction in which the first surface f1 and the second surface f2 are connected. The first surface f1 is substantially square-shaped and extends from the arrangement position of the circuit board 3 toward the motor rotation shaft 2a. This allows a relatively large connector arrangement area to be secured on the end surface side in the direction of the motor rotation shaft 2a. The angles Δ2 and Δ3 of the third surface f3 and the fourth surface f4 with respect to the first surface f1 and the second surface f2 at the joint portion 5 with the housing 1 are smaller than the predetermined angle, for example, 45 degrees. Of course, this angle is not limited to 45 degrees, and can be freely set as needed as long as it is smaller than 90 degrees.

[0014] The connector block 4 is provided with connectors 4a, 4b, 4c, and 4d arranged as shown in Fig. 2, and with power supply lines 6a and wiring 7a (including power supply line 6b and wiring 7b, not shown) for electrically connecting each of the connectors 4a, 4b, 4c, and 4d to electronic components or electronic circuits mounted on the circuit board 3 as shown in Fig. 4. The connectors are fixed to the fastening portions 8a, 8b, 8c, and 8d with screws or the like (not shown) so that the connector openings face the opposite side to the motor output shaft 2b of the housing 1.

[0015] Fig. 6 is a perspective view showing an example of the configuration of the joint 5 on the housing 1 side in the electric drive device shown in Fig. 1, and Fig. 7 is a perspective view showing an example of the configuration of the joint 5 on the connector block 4 side. The joint 5 between the housing 1 and the connector block 4 is provided with a seal structure. Furthermore, the joint between the first face f1 of the connector block 4 and the housing 1 and the joint between the second face f2 of the connector block 4 and the housing 1 have the same shape. This allows the opposing seal shapes to be symmetrical, and the seal can be shared even when the orientation of the connector block 4 is changed (rotated 180 degrees).

[0016] In addition, the installation surface of the connector opening in the connector block 4 is provided in the direction of the rotation shaft 2a of the electric motor 2 from the arrangement position of the circuit board 3. With this configuration, the connector opening can be arranged within the motor diameter, and the radial size can be suppressed. In other words, the size increase with respect to the motor diameter is minimal.

[0017] As shown in Fig. 6, the seal portion on the housing 1 side is a sealing groove 5a formed to surround the opening. Also, as shown in Fig. 7, the seal portion on the connector block 4 side is a sealing rib 5b formed to surround the opening and fitted into the sealing groove 5a. A viscous fluid-like hardening sealant is interposed between the sealing groove 5a and the sealing rib 5b to join them, thereby ensuring airtightness and waterproofing of the joint 5. In the connector block 4, power lines 6a, 6b and wiring 7a, 7b are provided for electrically connecting the connectors 4a, 4b, 4c, 4d to the electronic components or electronic circuits mounted on the circuit board 3.

[0018] In the sealing groove 5a in the joint 5 on the housing 1 side, the horizontal portions 5a-1 and 5a-2 have the same dimensions. Similarly, the vertical portions 5a-3 and 5a-4 also have the same dimensions. That is, the sealing portion is rectangular or square. This makes it possible to make the creepage distance of the sealing portion uniform and consistent when the orientation of the connector is changed, thereby preventing a decrease in airtightness and waterproofness.

[0019] Each seal may be a flat seal or a groove seal in which a protruding portion is inserted into a seal groove. In addition to a viscous fluid hardening sealant, a seal using an elastic body such as an O-ring may also be used.

[0020] 8 is a schematic diagram of an electric power steering device to which an electric drive device according to an embodiment of the present invention is applied. This electric power steering device 111 includes a steering mechanism 112 for performing steering based on an operation by a driver, and a steering assist mechanism 113 for assisting the steering operation of the driver. An electric motor 2 in the electric drive device 10 is used to assist the steering force, and this electric motor 2 is controlled by an electronic control unit (ECU) 3a to assist the steering operation.

[0021] The electric drive unit 10 is mounted on a gear rack 122, which will be described later. A connector portion of the electric drive unit 10 is electrically connected to a battery power source and electronic devices for in-vehicle communication (CAN: Controller Area Network communication) via a power supply harness (not shown) and a signal harness 134, and is also electrically connected to a torque sensor 124 and a steering angle sensor 123 via a sensor harness 135.

[0022] The steering mechanism 112 has a steering shaft (steering axis) 115 connected to a steering wheel 114, and a rack bar (steered axis) 118 connected to tires (steered wheels) 116, 117, and the steering shaft 115 and rack bar 118 are connected via a rack and pinion mechanism 119.

[0023] The steering shaft 115 is configured by connecting an input shaft 120 as a first shaft member that rotates integrally with the steering wheel 114 and an output shaft 121 as a second shaft member that links to a rack bar 118 by a torsion bar (not shown). One axial end of the input shaft 120 is connected to the steering wheel 114, and the other end is connected to the torsion bar. One axial end of the output shaft 121 is connected to the torsion bar, and the other end is linked to the rack bar 118.

[0024] Then, pinion teeth 121a formed on the outer periphery of the other end of the output shaft 121 mesh with rack teeth 118a formed on one end side of the rack bar 118 in the axial direction (longitudinal direction), thereby converting the rotational motion of the output shaft 121 into axial motion of the rack bar 118 and transmitting it.

[0025] Further, on the radially outer side (outer periphery side) of the steering shaft 115, a steering angle sensor 123 for detecting the steering angle, which is the rotation angle of the steering shaft 115, and a torque sensor 124 for detecting the steering torque applied to the steering shaft 115 by the steering operation of the driver are integrally provided as one unit. The steering angle sensor 123 detects the steering angle based on the difference in rotation angle between a pair of gears that rotate with the rotation of the steering shaft 115. The torque sensor 124 detects the steering torque based on the amount of relative rotational displacement between the input shaft 120 and the output shaft 121.

[0026] Tires 116, 117 are attached to both axial ends of the rack bar 118 via tie rods 125, 126 and knuckle arms (not shown). When the rack bar 118 moves in the axial direction and the knuckle arms are pushed and pulled via the tie rods 125, 126, the orientation of the tires 116, 117 is changed.

[0027] The steering assist mechanism 113 has an electric motor (electric actuator) 2 that generates a steering assist force, an electronic control device 3a that drives and controls the electric motor 2, and a transmission mechanism 133 that transmits the rotation of the electric motor 2 to the rack bar 118, and assists the axial movement of the rack bar 118 with the rotational force of the electric motor 2. The electronic control unit 3a is connected to another ECU, for example, a control unit for ESC (Electronic Stability Control) by a signal harness (CAN bus) 134, and transmits and receives information by CAN communication.

[0028] The electric motor 2 is driven and controlled based on the detection results of various sensors, such as an output signal S1 of the steering angle sensor 123 and an output signal S2 of the torque sensor 124 input to the electronic control device 3a via a sensor harness 135, an output signal S3 of a vehicle speed sensor (not shown) input via a signal harness (CAN bus) 134, and an output signal of a Hall IC that detects the rotation angle of the electric motor 2.

[0029] The transmission mechanism 133 has a reducer that reduces the speed of the rotation of the electric motor 2, and a conversion mechanism that converts the rotation of the reducer into axial motion of the rack bar 118. The reducer is composed of, for example, an input pulley fixed to the rotating shaft (drive shaft) 2a of the electric motor 2 so as to rotate integrally therewith, an output pulley fixed to a nut that functions as a conversion mechanism so as to be rotatable integrally therewith, and a belt or chain that is a transmission member wound around these pulleys.

[0030] The conversion mechanism may be, for example, a ball screw mechanism using a nut formed into a cylindrical shape so as to surround the rack bar 118. A nut-side ball screw groove is formed in a spiral shape on the inner circumference of the nut, and a steering shaft-side ball screw groove is formed in a spiral shape on the outer circumference of the rack bar 118. With the nut inserted into the rack bar 118, a ball circulation groove is formed by the nut-side ball screw groove and the steering shaft-side ball screw groove.

[0031] The ball circulation groove is filled with multiple metal balls, and when the nut rotates, the balls move inside the ball circulation groove, causing the rack bar 118 to move in the axial direction relative to the nut. The ball screw mechanism converts the rotational motion of the electric motor 2 into linear motion, and the rack bar 118 moves in the axial direction, pushing and pulling the knuckle arms via the tie rods 125, 126, applying a steering force to the tires 116, 117.

[0032] The reduction gear may be a worm gear having a worm shaft connected to the output shaft of the electric motor 2 so as to be rotatable together with the output shaft, and a worm wheel that rotates in mesh with the worm shaft. The conversion mechanism may be a so-called rack and pinion mechanism that is composed of pinion teeth formed on the outer periphery of the other axial end of the output shaft that rotates together with the worm wheel, and rack teeth formed on the other axial end of the rack bar 118 and that mesh with the pinion teeth.

[0033] Fig. 9 shows an extracted vicinity of the mounting portion when the electric drive unit of the first embodiment is applied to the electric power steering device shown in Fig. 8. The electric drive unit 10 is attached to a gear rack 122. The connectors 4a, 4c are arranged on the opposite side to the output shaft 2b of the electric motor 2, and a power harness (not shown), a signal harness 134, and a sensor harness 135 are inserted in the direction indicated by the dashed arrow AA (parallel to the gear rack 122) and are electrically connected to the battery power supply, electronic devices for in-vehicle communication, the torque sensor 124, and the steering angle sensor 123.

[0034] The rotation of the electric motor 2 is reduced and transmitted from an input pulley 136 fixed to rotate integrally with the motor rotating shaft 2a to an output pulley 137 fixed to rotate integrally with a nut that functions as a conversion mechanism, by a transmission member such as a belt 138 or a chain. The rotation reduced by this reducer is converted into axial motion of the rack bar 118 by the conversion mechanism, thereby assisting the steering operation of the driver.

[0035] 10 to 13 respectively show a schematic configuration example of a second mode of the electric drive device according to the first embodiment of the present invention, with Fig. 10 being a perspective view, Fig. 11 being a front view of the side opposite to the motor output shaft, Fig. 12 being a side view, and Fig. 13 being a sectional view taken along line X2-X2' in Fig. 10. In this second mode, the connector block 4 of the first mode is rotated 180 degrees and installed in the housing 1, so that the openings of the connectors 4a, 4b, 4c, and 4d are oriented in a direction perpendicular to the motor rotation shaft 2a.

[0036] The connector block 4 of the first embodiment is rotated 180 degrees at the joint 5, and the frontage of the connectors 4a, 4b, 4c, and 4d is changed to face upward and placed near the mounting surface of the circuit board 3. This makes it possible to shorten the power lines 6b and wiring 7b for electrically connecting the connectors 4a, 4b, 4c, and 4d to the electronic components or electronic circuits mounted on the circuit board 3, as shown in Fig. 13. Although not shown, it goes without saying that the power lines 6a and wiring 7a can also be shortened in a similar manner. Other basic configurations are similar to those in FIG. 1 to FIG. 4, so the same parts are given the same reference numerals and detailed description thereof is omitted.

[0037] Fig. 14 shows an extracted vicinity of the mounting portion when the electric drive unit of the second embodiment is applied to the electric power steering device shown in Fig. 8. The electric drive unit 10 is attached to a gear rack 122. The connectors 4a, 4b are arranged facing downward perpendicular to the output shaft 2b of the electric motor 2, and a power harness (not shown), a signal harness 134, and a sensor harness 135 are inserted from the direction indicated by arrow AB (perpendicular to the gear rack 122) and are electrically connected to the battery power supply, electronic devices for in-vehicle communication, the torque sensor 124, and the steering angle sensor 123.

[0038] In this way, the electronic control device 3a (circuit board 3) is disposed on the side surface of the electric motor 2, and the orientation of the connector opening is variable, that is, by changing the orientation of the connector block 4, the connector opening can be oriented in a different direction, in a direction perpendicular to the rack bar 118 in FIG. 14. Therefore, the connector opening can be disposed in a direction that does not interfere with the rack bar 118. Furthermore, with a small change such as changing the orientation of the connector block 4 for wiring, the electric drive device 10 can be adapted to electric power steering devices of different vehicle layouts. Furthermore, since the ECU housing that houses the circuit board 3 and the motor housing that houses the electric motor 2 are integrated, the sealing surfaces can be limited to the opposing positions of the two housings, preventing the sealing line from becoming complicated.

[0039] [Second embodiment] Figures 15 to 19 respectively show a schematic configuration example of a first form of an electric drive device according to a second embodiment of the present invention, with Figure 15 being a perspective view, Figure 16 being a front view of the side opposite to the motor output shaft, Figure 17 being a side view, Figure 18 being a sectional view taken along line X3-X3' in Figure 15, and Figure 19 being an exploded view. In the first form of this second embodiment, the connector block is disposed above the motor rotating shaft, and the ECU and the housing of the electric motor are separate entities.

[0040] That is, this electric drive device is configured such that the motor housing 1a and the ECU housing 1b are separate bodies, with the top end of the motor housing 1a and the bottom end of the ECU housing 1b joined together. The motor housing 1a accommodates an electric motor 2 having multiple independent winding sets, and the lower part of the ECU housing 1b accommodates a circuit board 3 on which an electronic control device is mounted. The mounting surface of the circuit board 3 for components is arranged horizontally with respect to the rotating shaft 2a of the electric motor 2. As a result, the circuit board 3 is accommodated in the motor housing 1a and the ECU housing 1b, ensuring a sufficient mounting area. The electronic control device mounted on the circuit board 3 is composed of electronic components and electronic circuits that control the drive of the electric motor 2.

[0041] The ECU housing 1b is sealed by a connector block 4 installed on the opposite side to the motor output shaft 2b. Power supply and communication connectors 4a, 4b and sensor connectors 4c, 4d are attached to the connector block 4. A joint 5 between the housing 1 and the connector block 4 is inclined at a predetermined angle, for example, 45 degrees, with respect to the rotating shaft 2a of the electric motor 2.

[0042] As in the first embodiment described above, the connector block 4 has a first surface (opening installation surface) f1 having an opening for the connectors 4a, 4b, 4c, and 4d, a second surface (vertical surface) f2 connected to the first surface f1 at a predetermined angle Δ1, for example, 90 degrees, and a third surface (side surface) f3 and a fourth surface (side surface) f4 located on both sides of the direction in which the first surface f1 and the second surface f2 are connected. The first surface f1 is substantially square-shaped and extends from the arrangement position of the circuit board 3 toward the motor rotation shaft 2a. This allows a relatively large connector arrangement area to be secured on the end surface side in the direction of the motor rotation shaft 2a. The angles Δ2 and Δ3 of the third surface f3 and the fourth surface f4 with respect to the first surface f1 and the second surface f2 at the joint portion 5 with the housing 1 are smaller than the predetermined angle, for example, 45 degrees. Of course, this angle is not limited to 45 degrees, and can be set to a predetermined angle as necessary as long as it is smaller than 45 degrees.

[0043] The connector block 4 is provided with connectors 4a, 4b, 4c, and 4d arranged as shown in Fig. 16, and with power lines 6a and wiring 7a (including power lines 6b and wiring 7b, not shown) for electrically connecting the connectors 4a, 4b, 4c, and 4d to electronic components or electronic circuits mounted on the circuit board 3 as shown in Fig. 18. The connectors are fixed to the fastening parts 8a, 8b, 8c, and 8d with screws or the like (not shown) so that the connector opening faces the opposite side to the motor output shaft 2b of the housing 1. The power lines 6a, 6b and wiring 7a, 7b are connected from the connectors 4a, 4b, 4c, and 4d to the circuit board 3 arranged at the bottom of the ECU housing 1b. Other basic configurations are similar to those of the first embodiment, so the same parts are given the same reference numerals and detailed descriptions thereof are omitted.

[0044] Figures 20 to 23 respectively show a schematic configuration example of a second mode of an electric drive device according to a second embodiment of the present invention, with Fig. 20 being a perspective view, Fig. 21 being a front view of the side opposite to the motor output shaft, Fig. 22 being a side view, and Fig. 23 being a sectional view taken along line X4-X4' in Fig. 20. In this second mode, the connector block 4 of the first mode is rotated 180 degrees at joint 5, and connectors 4a, 4b, 4c, and 4d are oriented in a direction perpendicular to the motor rotation shaft 2a.

[0045] The connector block 4 of the first form is rotated 180 degrees and the positions of each connector 4a, 4b, 4c, 4d are changed, so that the power supply lines 6b and wiring 7b (including the power supply lines 6a and wiring 7a, not shown) for electrically connecting the connectors 4a, 4b, 4c, 4d to the electronic components or electronic circuits mounted on the circuit board 3 are changed as shown in FIG. 23. Other basic configurations are similar to those in FIGS. 15 to 18, so the same parts are given the same reference numerals and detailed description thereof is omitted.

[0046] An electric drive device configured as in the second embodiment can obtain substantially the same effects as the first embodiment, except for whether the motor housing and the ECU housing are separate or integrated. The mounting surface of the connector opening of the connector block 4 extends beyond the motor housing in the direction opposite to the direction of the motor rotating shaft 2a from the arrangement position of the circuit board 3, making it possible to separate the motor housing 1a and the ECU housing 1b. This eliminates the need for a huge furnace in the sealing process, and also makes it possible to sell the ECU separately.

[0047] [Third embodiment] Fig. 24 to Fig. 28 respectively show a schematic configuration example of a first mode of an electric drive device according to a third embodiment of the present invention, with Fig. 24 being a perspective view, Fig. 25 being a front view of the side opposite to the motor output shaft, Fig. 26 being a side view, Fig. 27 being a sectional view taken along line X5-X5' in Fig. 24, and Fig. 28 being an exploded view. The first mode of this third embodiment is a specification obtained by inverting the first mode of the first embodiment upside down.

[0048] That is, the housing 1 is configured such that the lower part opposite the motor output shaft 2b is cut out at an angle of 45 degrees. The housing 1 accommodates an electric motor 2 having a plurality of independent winding sets and a circuit board 3 on which an electronic control device is mounted. The component mounting surface of the circuit board 3 is arranged horizontally with respect to the rotating shaft 2a of the electric motor 2. The electronic control device is composed of electronic components and electronic circuits that control the drive of the electric motor 2. The housing 1 is sealed by a connector block 4. Power supply and communication connectors 4a, 4b and sensor connectors 4c, 4d are attached to the connector block 4. A joint 5 between the housing 1 and the connector block 4 is inclined at a predetermined angle, for example, 135 degrees, with respect to the rotating shaft 2a of the electric motor 2.

[0049] The other configurations are similar to those of the first aspect of the first embodiment, so the same parts are given the same reference numerals and detailed descriptions thereof are omitted.

[0050] Figures 29 to 32 respectively show a schematic configuration example of a second mode of the electric drive device according to the third embodiment of the present invention, with Fig. 29 being a perspective view, Fig. 30 being a front view of the side opposite to the motor output shaft, Fig. 31 being a side view, and Fig. 32 being a sectional view taken along line X6-X6' in Fig. 29. In this second mode, the connector block 4 of the first mode is rotated 180 degrees at joint 5, so that the openings of connectors 4a, 4b, 4c, 4d face in a direction perpendicular to the motor rotation shaft 2a.

[0051] The connector block 4 of the first form is rotated 180 degrees at the joint 5 and the positions of the connectors 4a, 4b, 4c, and 4d are changed, so that the power lines 6a, 6b and wirings 7a, 7b for electrically connecting the connectors 4a, 4b, 4c, and 4d to the electronic components or electronic circuits mounted on the circuit board 3 are changed, as shown in Figure 27. Other basic configurations are similar to those in FIGS. 24 to 27, so the same parts are given the same reference numerals and detailed description thereof is omitted. Even with an electric drive device configured as in the third embodiment, the same effects as those of the first and second embodiments can be obtained, except that the motor housing and the ECU housing are separate or integrated.

[0052] [Fourth embodiment] Figures 33 to 36 respectively show a schematic configuration example of a first mode of an electric drive device according to a fourth embodiment of the present invention, with Fig. 33 being a perspective view, Fig. 34 being a side view, Fig. 35 being a sectional view taken along line X7-X7' in Fig. 33, and Fig. 36 being an exploded view. The first mode of the fourth embodiment is a modified version of the first mode of the third embodiment.

[0053] That is, the housing 1 is configured such that the lower part opposite the motor output shaft 2b is cut out at an angle of 45 degrees. The housing 1 accommodates an electric motor 2 having a plurality of independent winding sets and a circuit board 3 on which an electronic control device is mounted. The component mounting surface of the circuit board 3 is arranged horizontally with respect to the rotating shaft 2a of the electric motor 2. The electronic control device is composed of electronic components and electronic circuits that control the drive of the electric motor 2. The housing 1 is sealed by a connector block 4. Power supply and communication connectors 4a, 4b and sensor connectors 4c, 4d are attached to the connector block 4. A joint 5 between the housing 1 and the connector block 4 is inclined at a predetermined angle, for example, 135 degrees, with respect to the rotating shaft 2a of the electric motor 2.

[0054] The other configurations are similar to those of the first aspect of the first embodiment, so the same parts are given the same reference numerals and detailed descriptions thereof are omitted.

[0055] Figures 37 to 39 respectively show a schematic configuration example of a second mode of the electric drive device according to the fourth embodiment of the present invention, with Fig. 37 being a perspective view, Fig. 38 being a side view, and Fig. 39 being a cross-sectional view along line X8-X8' in Fig. 37. In this second mode, the connector block 4 of the first mode is rotated 180 degrees so that the openings of the connectors 4a, 4b, 4c, 4d face in a direction perpendicular to the motor rotation shaft 2a.

[0056] The connector block 4 of the first form is rotated 180 degrees and the positions of the connectors 4a, 4b, 4c, and 4d are changed, so that the power supply lines 6b and wiring 7b (including the power supply lines 6a and wiring 7a, not shown) for electrically connecting the connectors 4a, 4b, 4c, and 4d to the electronic components or electronic circuits mounted on the circuit board 3 are changed, as shown in Figure 39. Other basic configurations are similar to those in FIGS. 33 to 35, so the same parts are given the same reference numerals and detailed descriptions thereof are omitted. Even with an electric drive device configured as in the fourth embodiment, the same effects as those of the first to third embodiments can be obtained, except that the motor housing and the ECU housing are separate or integrated.

[0057] As described above, in the present invention, the angle of the third surface seal portion with respect to the first and second surfaces is set to an angle smaller than a predetermined angle (e.g., 45 degrees), so that the seal portion with an inclined surface can be formed, and when the connector block is rotated, for example, 180 degrees and assembled, the connector opening can be oriented in a different direction. This allows a selection of multiple (two) types of seal portion, making it easier to share the connector block.

[0058] In addition, when designing a product with a different connector opening direction, there is no need to redesign the connector outline or seal shape, thereby reducing development time. Furthermore, if there is a product requirement for the developed MCU (Motor Control Unit) that has the same performance but a different connector opening direction, it is possible to meet the requirement by simply redesigning the connector terminal shape.

[0059] Therefore, the only change that needs to be made is to the connector terminal, and most parts (such as the connector base) can be reused, which reduces the need for new investment in jigs / equipment costs for assembly. Furthermore, since the assembly can be performed without changing the fixing surface used in the equipment, the trajectory for applying the sealing material, or the conditions, the components can be used on the same production line.

[0060] The configurations, methods, etc. described in the above-mentioned embodiments are merely schematic illustrations to enable the present invention to be understood and practiced. Therefore, the present invention is not limited to the described embodiments, and may be modified in various forms without departing from the scope of the technical ideas set forth in the claims.

[0061] For example, we have explained an example in which the connector block is rotated 180 degrees at the joint to change the connector width in two directions, but it is also possible to make the joint square and rotate it 90 degrees at a time to change the connector width in four directions. Furthermore, although an example has been described in which the electric drive device is applied to an electric power steering device that assists the steering force of a vehicle, it goes without saying that the electric drive device may also be configured to control the steering of an autonomous vehicle. [Explanation of symbols]

[0062] Reference Signs List 1...housing, 1a...motor housing, 1b...ECU housing, 2...electric motor, 2a...rotating shaft, 2b...output shaft, 3...circuit board, 3a...electronic control device, 4...connector block, 4a, 4b...power supply and communication connectors (external terminals), 4c, 4d...sensor connectors (external terminals), 5...joint, 5a...sealing groove, 5b...sealing rib, 6a, 6b...power supply line, 7a, 7b...wiring, 8a, 8b, 8c, 8d...fastening portion, 10...electric drive unit, f1...first surface, f2...second surface, f3...third surface, f4...fourth surface

Claims

1. an electric motor having a plurality of independent winding sets; An electronic control device that controls the driving of the electric motor; a housing that accommodates a circuit board on which the electronic control device is mounted and the electric motor; a connector block to which external terminals are attached and which seals the housing; a seal portion interposed at a joint between the housing and the connector block; a mounting surface of the circuit board for mounting components is disposed horizontally with respect to a rotation shaft of the electric motor, The connector block has a first surface having a connector opening, a second surface connected to the first surface at a predetermined angle, and a third surface and a fourth surface located on both sides in a direction in which the first surface and the second surface are connected, an angle between the third surface and the fourth surface and the housing and the first surface and the second surface is smaller than the predetermined angle; An electric drive device characterized by:

2. 2. The electric drive device according to claim 1, wherein an angle between the first surface and the second surface is 90 degrees, and an angle between the first surface and the second surface at the joint between the third surface and the fourth surface and the housing is 45 degrees.

3. 3. The electric drive device according to claim 2, wherein a joint between the first surface of the connector block and the housing and a joint between the second surface of the connector block and the housing have the same shape.

4. 4. The electric drive device according to claim 3, wherein a mounting surface of the connector opening of the connector block extends from a position where the circuit board is disposed in a direction of a rotation axis of the electric motor.

5. 5. The electric drive device according to claim 4, wherein the circuit board is inserted into the housing from the direction of a rotation axis of the electric motor and is accommodated inside the housing.

6. 6. The electric drive device according to claim 5, wherein an installation surface of the connector opening of the connector block extends beyond the housing in a direction opposite to the direction of the rotational axis of the electric motor from the position where the circuit board is arranged.

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