Electric driving device and electric power steering device

Abstract

To provide an electric driving device and an electric power steering device, each being capable of keeping an enough waterproofness even under high water pressure.SOLUTION: An electric driving device comprises: a motor; and an electronic control device that controls a rotation of the motor. The electronic control device includes: a circuit board; a second housing; a metal lid that covers the second housing; and a sealing member. The lid includes: a first surface on an opposite load side; a back surface that is a side opposite to the first surface and is on a load side; and a sealing support portion that is projected in an annular shape on an opposite load side from the back surface, and is inserted into the inside of the second housing. The sealing support portion includes: a support portion that is opposite to an internal wall of the second housing; a distal end portion that is on the load side from the support portion, and includes an inclined surface having an outer periphery that becomes larger as directed to the opposite load side from the load side an outer side; and an annular groove portion in which a part of the outer periphery dents between the base portion and the distal end portion. The sealing member is nipped by the internal wall of the second housing and the groove portion of the sealing support portion.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] The present disclosure relates to an electric drive device and an electric power steering device that include an electronic control device that controls the rotation of a motor. [Background technology]

[0002] An electric power steering device that generates an auxiliary steering torque by means of a motor is equipped with an electronic control device that controls the motor (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2018 / 221726 Summary of the Invention [Problem to be solved by the invention]

[0004] In the electric drive device of Patent Document 1, the connector that connects to the circuit board is located on the outside of the motor when viewed in the axial direction of the shaft. The terminals of the connector penetrate a part (flange portion) of the housing of the electric drive device and connect to the circuit board. When the connector is aligned with the circuit board, two identical rod-shaped connecting members of the connector (see Figure 32 of Patent Document 1) are inserted. When the two connecting members are inserted into the circuit board, the positional relationship between the circuit board and the connector is regulated.

[0005] In the electric drive device of Patent Document 1, the positional relationship between the circuit board and the connector cannot be determined until the two connecting members and the through holes provided in the circuit board are aligned, which may result in a long takt time for attaching the connector.

[0006] The present disclosure has been made in consideration of the above-mentioned problems, and aims to provide an electric drive device and an electric power steering device that are capable of positioning the terminals of the connector relative to the circuit board and the housing while improving the ease of assembling the connector. [Means for solving the problem]

[0007] In order to achieve the above object, one aspect of the electric drive device is an electric drive device including a motor and an electronic control device that controls rotation of the motor, wherein the motor includes a shaft extending in an axial direction from a load side to an anti-load side, a motor rotor that interlocks with the shaft, a motor stator that rotates the motor rotor, a housing that houses the motor rotor and the motor stator inside, and a flange portion provided on the anti-load side of the housing, and the electronic control device includes a circuit board and a connector that is fixed to the flange portion and connects to the circuit board. The connector has a first connector terminal that protrudes from the base of the connector toward the anti-load side and connects to the circuit board, and a first reference pin that protrudes from the base of the connector toward the anti-load side, has a tip that is on the anti-load side of the first connector terminal, and the tip is inserted into a first through hole of the circuit board, and the motor has a convex portion that protrudes from the load side to the anti-load side to a height that can be abutted by a stop portion of a part of the end face of the circuit board when the tip of the first reference pin is inserted into the first through hole of the circuit board and the first connector terminal is not connected to the circuit board.

[0008] This allows the circuit board to be simply aligned with the first reference pin and inserted into the first through-hole of the circuit board. The abutment portion of the circuit board is aligned with the protrusion of the motor. This regulates not only the relative positional relationship between the connector and the circuit board, but also the relative positional relationship between the motor housing and the circuit board. As a result, simply moving the positioned circuit board in the load direction determines not only the relative positional relationship between the circuit board and the first connector terminals, but also the fixed position of the circuit board relative to the motor housing. As a result, it is possible to position the first connector terminals relative to the circuit board and the housing while improving the efficiency of connector assembly.

[0009] In a preferred embodiment, the first reference pin has a tapered portion whose diameter decreases toward the tip, which allows the circuit board to rotate about the first reference pin when the tip of the first reference pin is inserted into the through-hole of the circuit board and the first connector terminal is not connected to the circuit board.

[0010] In a preferred embodiment, the flange portion includes a base portion of the flange portion, a second through hole penetrating the base portion of the flange portion, and a slit penetrating the base portion of the flange portion and extending outward from the second through hole, and the connector has a guide wall extending outward from the first reference pin, the first reference pin being inserted into the second through hole, and the guide wall being inserted into the slit. Thus, the position and orientation of the connector relative to the flange portion are regulated by the first reference pin and the guide wall, making it easier to insert the connector parallel to the axial direction.

[0011] In a preferred embodiment, the flange portion includes a third through-hole penetrating a base portion of the flange portion, the connector includes a first reinforcing wall into which the first connector terminal is fitted, and the guide wall connects the first reinforcing wall to the first reference pin. This allows the first reference pin to be supported by the guide wall, which acts as a rib. As a result, bending of the first reference pin is suppressed.

[0012] In a preferred embodiment, the flange portion includes a fixing hole provided on the anti-load side of the base, and the connector has a second reference pin that protrudes from the base of the connector toward the anti-load side and has a tip that is further on the anti-load side than the tip of the first reference pin, and the second reference pin is inserted into the fixing hole. This makes it easier for the second reference pin to enter the fixing hole, improving assembly workability.

[0013] In a preferred embodiment, a gap filled with a form-in-place gasket is formed between the flange and the connector. The first and second reference pins regulate the positional relationship of the connector with respect to the flange, thereby stably forming the gap filled with the form-in-place gasket.

[0014] In a preferred embodiment, the electric power steering system includes an electric drive unit, and the electric drive unit generates the auxiliary steering torque. [Effects of the Invention]

[0015] According to the present disclosure, it is possible to provide an electric drive device and an electric power steering device that can improve the ease of assembly when attaching a cover to a housing, provide waterproofing, and position the cover relative to the housing. [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 is a perspective view that schematically shows a vehicle equipped with an electric power steering device according to the first embodiment. [Figure 2] FIG. 2 is a schematic diagram of the electric power steering device according to the first embodiment. [Figure 3] FIG. 3 is a cross-sectional view schematically showing a cross section of the motor according to the first embodiment. [Figure 4] FIG. 4 is a schematic diagram showing wiring of the motor according to the first embodiment. [Figure 5] FIG. 5 is a schematic diagram showing the relationship between the motor and the ECU according to the first embodiment. [Figure 6] FIG. 6 is a side view of the electric drive device according to the first embodiment. [Figure 7] FIG. 7 is a plan view of the electric drive device according to the first embodiment. [Figure 8] FIG. 8 is a perspective view of the electric drive device according to the first embodiment with the cover removed. [Figure 9] FIG. 9 is a perspective view of the back surface of the lid according to the first embodiment. [Figure 10] FIG. 10 is a plan view of the electric drive device according to the first embodiment with the circuit board removed. [Figure 11] FIG. 11 is a cross-sectional view taken along the line XI-XI in FIG. [Figure 12] FIG. 12 is a cross-sectional view showing an enlarged partial cross section of a portion Q1 in FIG. [Figure 13] 13 is a cross-sectional view taken along the line XII-XII in FIG. [Figure 14] 14 is a cross-sectional view taken along the line XIV-XIV in FIG. 8. FIG. [Figure 15] FIG. 15 is a perspective view illustrating the connector according to the first embodiment. [Figure 16] FIG. 16 is a perspective view illustrating the anti-load side of the flange portion according to the first embodiment. [Figure 17] FIG. 17 is a perspective view illustrating an assembly operation of the connector according to the first embodiment. [Figure 18] FIG. 18 is a perspective view illustrating an assembly operation of the connector according to the first embodiment. [Figure 19] FIG. 19 is a schematic diagram of an electric power steering device according to the second embodiment. [Figure 20] FIG. 20 is a schematic diagram of an electric power steering device according to the third embodiment. [Figure 21] FIG. 21 is a schematic diagram of an electric power steering device according to the fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0017] Modes (embodiments) for carrying out the present disclosure will be described in detail with reference to the drawings. The present disclosure is not limited to the contents described in the following embodiments. Furthermore, the components described below include those that can be easily imagined by a person skilled in the art and those that are substantially identical. Furthermore, the components described below can be combined as appropriate.

[0018] (Embodiment 1) Fig. 1 is a perspective view that schematically shows a vehicle equipped with an electric power steering device according to embodiment 1. Fig. 2 is a schematic diagram of the electric power steering device according to embodiment 1. As shown in Fig. 1, a vehicle 101 is equipped with an electric power steering device 100. An overview of the electric power steering device 100 will be described with reference to Fig. 2.

[0019] The electric power steering device 100 includes, in the order in which a force applied by a driver (operator) is transmitted, a steering wheel 191, a steering shaft 192, a universal joint 196, an intermediate shaft 197, a universal joint 198, a first rack-and-pinion mechanism 199, and a tie rod 172. The electric power steering device 100 also includes a torque sensor 194 that detects the steering torque of the steering shaft 192, a motor 30, an electronic control unit (hereinafter referred to as an ECU (Electronic Control Unit)) 10 that controls the motor 30, and a reduction gear 175. A vehicle speed sensor 182, a power supply device 183 (e.g., an on-board battery), and an ignition switch 184 are provided on the vehicle body. The vehicle speed sensor 182 detects the traveling speed of the vehicle 101. The vehicle speed sensor 182 outputs the detected vehicle speed signal SV to the ECU 10 via CAN (Controller Area Network) communication. The ECU 10 is supplied with power from a power supply device 183 when an ignition switch 184 is in an on state.

[0020] As shown in Fig. 2, the steering shaft 192 includes an input shaft 192A and an output shaft 192B. One end of the input shaft 192A is connected to the steering wheel 191, and the other end is connected to the torsion bar. One end of the output shaft 192B is connected to the torsion bar, and the other end is connected to a universal joint 196. The torque sensor 194 detects the torsion of the torsion bar to detect the steering torque applied to the steering shaft 192. The torque sensor 194 outputs a steering torque signal T corresponding to the detected steering torque to the ECU 10. The steering shaft 192 rotates due to the steering force applied to the steering wheel 191.

[0021] Intermediate shaft 197 transmits torque from output shaft 192B. First rack and pinion mechanism 199 has a first pinion shaft 199A, a first pinion gear 199B, a rack shaft 199C, and a first rack 199D. One end of first pinion shaft 199A is connected to intermediate shaft 197 via universal joint 198, and the other end is connected to first pinion gear 199B. First rack 199D formed on rack shaft 199C meshes with first pinion gear 199B.

[0022] As described above, the rotational motion of the steering shaft 192 is transmitted to the first rack and pinion mechanism 199 via the intermediate shaft 197. This rotational motion is converted into linear motion of the rack shaft 199C by the first rack and pinion mechanism 199. The tie rods 172 are connected to both ends of the rack shaft 199C.

[0023] The motor 30 generates an auxiliary steering torque to assist the driver in steering, and may be a brushless motor or a brush motor having brushes and a commutator.

[0024] The ECU 10 includes a rotation angle sensor 23a. The rotation angle sensor 23a detects the rotation phase of the motor 30. The ECU 10 acquires a rotation phase signal of the motor 30 from the rotation angle sensor 23a, acquires a steering torque signal T from the torque sensor 194, and acquires a vehicle speed signal SV of the vehicle 101 from the vehicle speed sensor 182. The ECU 10 calculates an assist steering command value of the assist command based on the rotation phase signal, the steering torque signal T, and the vehicle speed signal SV. The ECU 10 supplies a current to the motor 30 based on the calculated assist steering command value.

[0025] The electric drive device 1 includes a motor 30 and an ECU 10 fixed to the anti-load side of the shaft of the motor 30. The electric drive device 1 may also include an adapter that connects the ECU 10 and the motor 30.

[0026] The reduction gear 175 includes a worm shaft that rotates integrally with the shaft 31 of the motor 30, and a worm wheel that meshes with the worm shaft. Therefore, the rotational motion of the shaft of the motor 30 is transmitted to the worm wheel via the worm shaft. In the first embodiment, the end of the motor shaft on the reduction gear 175 side is referred to as the load side end, and the end of the motor shaft opposite the reduction gear 175 is referred to as the anti-load side end.

[0027] The steering force of the driver input to the steering wheel 191 is transmitted to the first rack-and-pinion mechanism 199 via the steering shaft 192 and the intermediate shaft 197. The first rack-and-pinion mechanism 199 transmits the transmitted steering force to the rack shaft 199C as a force applied in the axial direction of the rack shaft 199C. At this time, the ECU 10 acquires the steering torque signal T input to the steering shaft 192 from the torque sensor 194. The ECU 10 acquires the vehicle speed signal SV from the vehicle speed sensor 182. The ECU 10 acquires the rotation phase signal of the motor 30 from the rotation angle sensor 23a. The ECU 10 then outputs a control signal to control the operation of the motor 30. The auxiliary steering torque generated by the motor 30 is transmitted to the output shaft 192B via the reduction gear 175. In this manner, the electric power steering device 100 assists the steering of the steering wheel 191 by the driver.

[0028] As shown in FIG. 2, the electric power steering device 100 is of a column assist type in which an assist force is applied to the output shaft 192B of the steering shaft 192.

[0029] FIG. 3 is a cross-sectional view schematically illustrating a cross section of the motor according to the first embodiment. FIG. 4 is a schematic diagram illustrating wiring of the motor according to the first embodiment. In the first embodiment, the circumferential direction is a direction along a concentric circle centered on the shaft 31. The radial direction is a direction away from the shaft 31 in a plane perpendicular to the axial direction AX. As shown in FIG. 3, the motor 30 includes a housing 930, a motor stator having a stator core 931, and a motor rotor 932. The motor stator includes the cylindrical stator core 931, a plurality of first coils 37, and a plurality of second coils 38. The stator core 931 includes an annular back yoke 931a and a plurality of teeth 931b protruding from the inner circumferential surface of the back yoke 931a. Twelve teeth 931b are arranged in the circumferential direction. The motor rotor 932 includes a rotor yoke 932a and a magnet 932b. The magnets 932b are provided on the outer peripheral surface of the rotor yoke 932a. The number of magnets 932b is, for example, 8. The rotation of the motor rotor 932 is linked to the rotation of the shaft 31.

[0030] As shown in FIG. 3, the first coil 37 is concentratedly wound around each of the multiple teeth 931b. The first coil 37 is concentratedly wound around the outer periphery of the tooth 931b with an insulator interposed therebetween. All of the first coils 37 are included in a first coil system. The first coil system according to the first embodiment is supplied with current and excited by a first inverter circuit 251A (see FIG. 5) included in the first power circuit 25A. The first coil system includes, for example, six first coils 37. The six first coils 37 are arranged so that two first coils 37 are adjacent to each other in the circumferential direction. Three first coil groups Gr1, each consisting of adjacent first coils 37, are arranged at equal intervals in the circumferential direction. That is, the first coil system includes three first coil groups Gr1 arranged at equal intervals in the circumferential direction. The number of first coil groups Gr1 does not necessarily have to be three; it is sufficient that 3n first coil groups Gr1 are arranged at equal intervals in the circumferential direction, where n is a natural number. Furthermore, it is preferable that n is an odd number. As described above, in the first embodiment, there are a plurality of coil groups, and each of the three phases is divided into at least two systems, a first coil group Gr1 and a second coil group Gr2, and the stator core is excited by three-phase AC.

[0031] As shown in FIG. 3, the second coil 38 is concentratedly wound around each of the multiple teeth 931b. The second coil 38 is concentratedly wound around the outer periphery of the teeth 931b with an insulator interposed therebetween. The teeth 931b around which the second coil 38 is concentratedly wound are different from the teeth 931b around which the first coil 37 is concentratedly wound. All of the second coils 38 are included in a second coil system. The second coil system is supplied with current and excited by a second inverter circuit 251B (see FIG. 5) included in the second power circuit 25B. The second coil system includes, for example, six second coils 38. The six second coils 38 are arranged so that two second coils 38 are adjacent to each other in the circumferential direction. Three second coil groups Gr2, each consisting of adjacent second coils 38, are arranged at equal intervals in the circumferential direction. That is, the second coil system includes three second coil groups Gr2 arranged at equal intervals in the circumferential direction. The number of second coil groups Gr2 does not necessarily have to be three, but may be 3n, where n is a natural number, and it is preferable that n is an odd number.

[0032] 4, the six first coils 37 include two first U-phase coils 37Ua and 37Ub excited by a first U-phase current I1u, two first V-phase coils 37Va and 37Vb excited by a first V-phase current I1v, and two first W-phase coils 37Wa and 37Wb excited by a first W-phase current I1w. 1U-phase coil 37Ub is connected in series to 1U-phase coil 37Ua. 1V-phase coil 37Vb is connected in series to 1V-phase coil 37Va. 1W-phase coil 37Wb is connected in series to 1W-phase coil 37Wa. All of the first coils 37 are wound in the same direction around teeth 931b. Furthermore, first U-phase coil 37Ub, first V-phase coil 37Vb, and first W-phase coil 37Wb are joined together in a star connection (Y connection).

[0033] 4, the six second coils 38 include two second U-phase coils 38Ua and 38Ub excited by a second U-phase current I2u, two second V-phase coils 38Va and 38Vb excited by a second V-phase current I2v, and two second W-phase coils 38Wa and 38Wb excited by a second W-phase current I2w. 2U-phase coil 38Ub is connected in series to 2U-phase coil 38Ua. 2V-phase coil 38Vb is connected in series to 2V-phase coil 38Va. 2W-phase coil 38Wb is connected in series to 2W-phase coil 38Wa. The winding directions of all second coils 38 about teeth 931b are the same as the winding direction of first coil 37. Furthermore, the second U-phase coil 38Ub, the second V-phase coil 38Vb, and the second W-phase coil 38Wb are joined together in a star connection (Y connection).

[0034] 3, the three first coil groups Gr1 are comprised of a first UV coil group Gr1UV, a first VW coil group Gr1VW, and a first UW coil group Gr1UW. The first UV coil group Gr1UV includes a first U-phase coil 37Ub and a first V-phase coil 37Va that are adjacent to each other in the circumferential direction. The first VW coil group Gr1VW includes a first V-phase coil 37Vb and a first W-phase coil 37Wa that are adjacent to each other in the circumferential direction. The first UW coil group Gr1UW includes a first U-phase coil 37Ua and a first W-phase coil 37Wb that are adjacent to each other in the circumferential direction.

[0035] 3, the three second coil groups Gr2 are composed of a second UV coil group Gr2UV, a second VW coil group Gr2VW, and a second UW coil group Gr2UW. The second UV coil group Gr2UV includes a second U-phase coil 38Ub and a second V-phase coil 38Va that are adjacent to each other in the circumferential direction. The second VW coil group Gr2VW includes a second V-phase coil 38Vb and a second W-phase coil 38Wa that are adjacent to each other in the circumferential direction. The second UW coil group Gr2UW includes a second U-phase coil 38Ua and a second W-phase coil 38Wb that are adjacent to each other in the circumferential direction.

[0036] First coil 37, which is excited by first U-phase current I1u, faces second coil 38, which is excited by second U-phase current I2u, in the radial direction of stator core 931. In the following description, the radial direction of stator core 931 will be simply referred to as the radial direction. For example, as shown in FIG. 3, first U-phase coil 37Ua faces second U-phase coil 38Ua, and first U-phase coil 37Ub faces second U-phase coil 38Ub in the radial direction.

[0037] First coil 37, excited by first V-phase current I1v, faces, in the radial direction, second coil 38, excited by second V-phase current I2v. For example, as shown in Fig. 3, first V-phase coil 37Va faces, in the radial direction, second V-phase coil 38Va, and first V-phase coil 37Vb faces, in the radial direction, second V-phase coil 38Vb.

[0038] First coil 37, which is excited by first W-phase current I1w, faces, in the radial direction, second coil 38, which is excited by second W-phase current I2w. For example, as shown in Fig. 3, first W-phase coil 37Wa faces, in the radial direction, second W-phase coil 38Wa, and first W-phase coil 37Wb faces, in the radial direction, second W-phase coil 38Wb.

[0039] Fig. 5 is a schematic diagram showing the relationship between the motor and the ECU according to embodiment 1. As shown in Fig. 5, the ECU 10 includes a detection circuit 23, a control circuit 24, a first power circuit 25A, a second power circuit 25B, a power supply management circuit 27, a breaker drive circuit 243, and a power supply relay drive circuit 246. Note that in Fig. 5, circuits that do not require explanation are omitted as appropriate.

[0040] The control circuit 24 has a control arithmetic circuit 241, a first motor drive circuit 26A, and a second motor drive circuit 26B. Input / output signals such as a steering torque signal T and a vehicle speed signal SV are transmitted to the control arithmetic circuit 241 via a connector CNT. Since the circuit board 20 is a multilayer resin board provided with multiple conductive layers, the connection wiring electrically connecting the connector CNT to the control arithmetic circuit 241 of the control circuit 24 is routed on the internal conductive layers of the circuit board 20.

[0041] Power is supplied to the wiring PW from the power supply device 183 via a connector CNT. The noise filter circuit 90 has a choke coil 91 and a capacitor 92, and removes high-frequency components superimposed on the power supplied from the wiring PW. The connection wiring PWS routed to the circuit board 20 is connected to the wiring PW from the power supply device 183. One end of the connection wiring PWS is connected to the noise filter circuit 90 (choke coil 91, capacitor 92), and the other end of the connection wiring is connected to the first inverter circuit 251A of the first power circuit 25A or the second inverter circuit 251B of the second power circuit 25B via a power supply circuit 256. When the first inverter circuit 251A and the second inverter circuit 251B are not to be distinguished from each other, they will be simply referred to as the inverter circuit 251.

[0042] The power supply circuit 256 is disposed between the noise filter circuit 90 and the inverter circuit 251. The power supply circuit 256 includes a power cutoff element 257 and a reverse connection protection element 258. The power cutoff element 257 and the reverse connection protection element 258 are field effect transistors (FETs). The forward direction of the parasitic diode of the reverse connection protection element 258 is opposite to the forward direction of the parasitic diode of the power cutoff element 257. Therefore, even if reverse polarity power is mistakenly supplied from the power supply device 183, the reverse connection protection element 258 cuts off the reverse polarity power and protects the inverter circuit 251.

[0043] The power supply management circuit 27 is a switching IC that controls the ON / OFF of the power supply and the distribution of power to the circuits mounted on the circuit board 20. The power supply management circuit 27 controls, for example, the distribution of power used by the control circuit 24. One end of the connection wiring is connected to the noise filter circuit 90 (choke coil 91, capacitor 92), and the other end of the connection wiring is connected to the power supply management circuit 27.

[0044] The detection circuit 23 has two rotation angle sensors 23a and a sensor control unit 23b. The detection circuit 23 can continue to function even if one rotation angle sensor 23a fails. The first power circuit 25A has a first inverter circuit 251A and a current interruption circuit 255. The second power circuit 25B has a second inverter circuit 251B and a current interruption circuit 255.

[0045] The first motor drive circuit 26A has a first gate drive circuit 242a, multiple current detection circuits 244, and a boost circuit 245. The second motor drive circuit 26B has a second gate drive circuit 242b, multiple current detection circuits 244, and a boost circuit 245. The boost circuit 245 supplies boosted power to the first gate drive circuit 242a, the second gate drive circuit 242b, the breaker drive circuit 243, and the power relay drive circuit 246.

[0046] When the power relay drive circuit 246 turns on the power cutoff element 257 and the reverse connection protection element 258 based on the control of the control calculation circuit 241 , power from the power supply device 183 is supplied to each inverter circuit 251 .

[0047] The inverter circuit 251 also has a plurality of drive elements 252. The drive elements 252 are field effect transistors (FETs), also called switching elements. The drive elements 252 connected to the high potential side constitute an upper arm, and the drive elements 252 connected to the low potential side constitute a lower arm. A shunt resistor SR is connected to each of the three drive elements 252 in the lower arm. Note that one shunt resistor SR is connected to each of the three drive elements 252, but only one shunt resistor SR may be connected to each of the three drive elements 252.

[0048] The control and calculation circuit 241 controls the first motor drive circuit 26A or the second motor drive circuit 26B. For example, the control and calculation circuit 241 calculates a motor current command value and controls the first motor drive circuit 26A or the second motor drive circuit 26B using the motor current command value. The sensor control unit 23b calculates the motor electrical angle θm based on the detection value of the rotation angle sensor 23a and outputs it to the control and calculation circuit 241. The first gate drive circuit 242 controls the first power circuit 25A based on the motor current command value. The second gate drive circuit 242b controls the second power circuit 25B based on the motor current command value. In this way, the current flowing to the first coil 37 and the current flowing to the second coil 38 are each independently controlled by the control and calculation circuit 241.

[0049] 5, the ECU 10 includes a rotation angle sensor 23a. The rotation angle sensor 23a is, for example, a magnetic sensor. A detection value of the rotation angle sensor 23a is supplied to a sensor control unit 23b. The sensor control unit 23b outputs an output value corresponding to the motor electrical angle θm to a control calculation circuit 241 based on the detection value of the rotation angle sensor 23a.

[0050] The control calculation circuit 241 receives as input the steering torque signal T detected by the torque sensor 194, the vehicle speed signal SV detected by the vehicle speed sensor 82, and an output value corresponding to the motor electrical angle θm output from the sensor control unit 23b. The control calculation circuit 241 calculates a motor current command value based on the steering torque signal T, the vehicle speed signal SV, and the motor electrical angle θm calculated from the above output value, and outputs the motor current command value to the first gate drive circuit 242a and the second gate drive circuit 242b.

[0051] First gate drive circuit 242a calculates a first pulse-width modulated signal based on the motor current command value and outputs the gate drive signal to first inverter circuit 251A of first power circuit 25A. The gate drive signal is a pulse signal generated based on the gate voltage boosted by boost circuit 245. First inverter circuit 251A switches drive element 252 to generate three-phase current values ​​according to the duty ratio of the first pulse-width modulated signal, thereby generating a three-phase AC current including a first U-phase current I1u, a first V-phase current I1v, and a first W-phase current I1w. The first U-phase current I1u excites first U-phase coil 37Ua and first U-phase coil 37Ub, the first V-phase current I1v excites first V-phase coil 37Va and first V-phase coil 37Vb, and the first W-phase current I1w excites first W-phase coil 37Wa and first W-phase coil 37Wb.

[0052] Second gate drive circuit 242b calculates a second pulse-width modulated signal based on the motor current command value and outputs the gate drive signal to second inverter circuit 251b of second power circuit 25B. The gate drive signal is generated based on the voltage boosted by boost circuit 245. Second inverter circuit 251b switches drive element 252 to generate three-phase current values ​​according to the duty ratio of the second pulse-width modulated signal, thereby generating a three-phase AC current including a second U-phase current I2u, a second V-phase current I2v, and a second W-phase current I2w. The second U-phase current I2u excites second U-phase coil 38Ua and second U-phase coil 38Ub, the second V-phase current I2v excites second V-phase coil 38Va and second V-phase coil 38Vb, and the second W-phase current I2w excites second W-phase coil 38Wa and second W-phase coil 38Wb.

[0053] The inverter circuit 251 is a power conversion circuit that converts DC power into AC power. As described above, the inverter circuit 251 has a plurality of drive elements 252. The drive elements 252 are, for example, field-effect transistors. A smoothing capacitor 253 is connected in parallel to the inverter circuit 251. The capacitor 253 is, for example, an electrolytic capacitor. In other words, the circuit board 20 includes a plurality of electrolytic capacitors connected in parallel.

[0054] The current detection circuit 244 is also connected to, for example, a shunt resistor SR. The shunt resistor SR is an example of a current detection element. The current detection element may be a Hall element or the like. The current detection circuit 244 includes a differential amplifier circuit using an operational amplifier and a low-pass filter. The differential amplifier circuit of the current detection circuit 244 amplifies the signal of the detection value detected by the shunt resistor SR, attenuates components higher than the cutoff frequency of the amplified detection value via a low-pass filter, and sends the detection value detected by the shunt resistor SR to the control calculation circuit 241 as a current value.

[0055] The current interruption circuit 255 is disposed between the inverter circuit 251 and the first coil 37 or the second coil 38. If the current value detected by the current detection circuit 244 is determined to be abnormal, the control and calculation circuit 241 drives the current interruption circuit 255 via the interruption drive circuit 243 to interrupt the current flowing from the inverter circuit 251 to the first coil 37. The control and calculation circuit 241 also drives the current interruption circuit 255 via the interruption drive circuit 243 to interrupt the current flowing from the inverter circuit 251 to the second coil 38. If the current value detected by the current detection circuit 244 is determined to be abnormal, the control and calculation circuit 241 turns off the power interruption element 257 and the reverse connection protection element 258 via the power relay drive circuit 246 to protect the inverter circuit 251.

[0056] FIG. 6 is a side view of the electric drive device according to the first embodiment. FIG. 7 is a plan view of the electric drive device according to the first embodiment. FIG. 8 is a perspective view of the electric drive device according to the first embodiment with the cover removed. FIG. 9 is a perspective view of the back side of the cover according to the first embodiment. FIG. 10 is a plan view of the electric drive device according to the first embodiment with the circuit board removed. FIG. 11 is a cross-sectional view taken along the line XI-XI in FIG. 6. FIG. 12 is a cross-sectional view showing an enlarged partial cross-section of portion Q1 in FIG. 11. FIG. 13 is a cross-sectional view taken along the line XII-XII in FIG. 6. As shown in FIGS. 6 and 7, the electric drive device 1 includes a motor 30 and an ECU 10 arranged on the anti-load side of the motor 30.

[0057] As shown in Figures 6 and 7, the ECU 10 includes a flange portion 40 and a cover 50 that covers the anti-load side of the motor 30. As shown in Figures 6 and 7, the cover 50 is fixed by being sandwiched between the flange portion 40 and the head of a bolt CT, which is a fixing member. As shown in Figures 8, 10, and 11, the flange portion 40 protrudes radially outward beyond the inner wall of the housing 930. In the embodiment, the flange portion 40 is formed integrally with the housing 930, but it may also be possible for the flange portion 40 to be separate from the housing 930, and for the flange portion 40 and the housing 930 to be fixed together with bolts or the like.

[0058] As shown in Fig. 8, a connector CNT is attached to the load side of the flange portion 40. The connector CNT includes a first connector terminal PPW that supplies power, a second connector terminal PCN that serves as a communication terminal for performing CAN communication, and a third connector terminal PTS that serves as a communication terminal for inputting and outputting data by a method other than CAN communication. The first connector terminal PPW is electrically connected to a first connection region APW of the circuit board 20. The second connector terminal PCN is electrically connected to a second connection region ACN of the circuit board 20. The third connector terminal PTS is electrically connected to a third connection region ATS of the circuit board 20.

[0059] 8, the first reference pin P1 is inserted into a first through-hole 20H (see FIG. 14) in the region AP1. The first reference pin P1 protrudes from the circuit board 20 further than the first connector terminal PPW, the second connector terminal PCN, and the third connector terminal PTS.

[0060] As shown in Fig. 8, the flange portion 40 supports the circuit board 20 via a bearing holder 60 and a bolt BT1. As shown in Figs. 8 and 10, the bearing holder 60 has a protrusion 60L that protrudes further toward the anti-load side than the anti-load side surface of the base portion 61 of the bearing holder 60. As shown in Fig. 8, a part of the end face of the circuit board 20 forms an abutment portion 20L. When the abutment portion 20L abuts against the protrusion 60L of the bearing holder 60, it becomes easier to position the circuit board 20 relative to the bearing holder 60, and the bolt BT2, when it has penetrated the circuit board 20, becomes easier to fit into the female thread portion FH1.

[0061] 8, which is a fixing member, penetrates the circuit board 20 and is fastened to a female thread FH1 formed in the support pillar shown in Fig. 10. The circuit board 20 is fixed by being sandwiched between the support pillar 66 of the bearing holder 60 and the head of the bolt BT1.

[0062] 10, a bolt BT1 which is a fixing member, passes through a positioning portion 69 of the bearing holder 60 and is fastened to a female thread portion (not shown) formed in the flange portion 40. As shown in FIGS. 8 and 10, the bearing holder 60 is fixed by being sandwiched between the flange portion 40 and the head of the bolt BT2.

[0063] The flange portion 40 has a base portion 41, a flange upper surface 41F (first surface), a groove portion 42, three position restriction portions 43, and a protrusion portion 45. The flange upper surface 41F (first surface), the groove portion 42, and the protrusion portion 45 are each annular, and are arranged so as to surround the outside of the circuit board 20 and the bearing holder 60. The protrusion portion 45, the groove portion 42, and the flange upper surface 41F (first surface) are arranged from the radially inner side to the radially outer side.

[0064] The protrusion 45 is an annular wall that protrudes toward the anti-load side from the base 41. The top of the protrusion 45 on the anti-load side is a plane that is perpendicular to the axial direction AX.

[0065] 10 and 11, the size of the bearing holder 60 when viewed in the axial direction AX is such that it can fit inside the support portion 52 of the lid 50. As shown in FIG. 11, the edge of the bearing holder 60 is positioned so that it overlaps the upper surface of the protrusion 45. This eliminates the need to seal between the bearing holder 60 and the lid 50, and between the bearing holder 60 and the flange 40. In the electric drive unit 1 of the first embodiment, it is sufficient to seal between the flange upper surface 41F and the edge portion 51 of the lid 50.

[0066] The flange upper surface 41F is an opposing surface facing the edge lower surface 51F (second surface) of the edge portion 51 of the lid 50. The flange upper surface 41F is a plane perpendicular to the axial direction AX. Over most of the flange upper surface 41F, the radial length of the flange upper surface 41F is greater than the radial length of the top of the protrusion 45 on the anti-load side.

[0067] The groove 42 is provided between the flange upper surface 41F and the protruding portion 45 and between the position restricting portion 43 and the protruding portion 45, and is an annular recess recessed below the flange upper surface 41F.

[0068] The position restricting portion 43 is an island-shaped portion on the flange upper surface 41F that protrudes from the flange upper surface 41F. The number of position restricting portions 43 is not limited to three, as long as there is more than one. The apex of the position restricting portion 43 on the anti-load side is a plane that is perpendicular to the axial direction AX. The apex of the position restricting portion 43 on the anti-load side is closer to the flange upper surface 41F than the apex of the protruding portion 45 on the anti-load side.

[0069] 8 supports the circuit board 20. The circuit board 20 is fixed to one surface (anti-load side) of the bearing holder 60. The flange portion 40 is made of a metal material with high heat dissipation properties, such as aluminum or copper, and also functions as a heat sink that transfers heat generated by electronic components mounted on the circuit board 20 to the flange portion 40.

[0070] For example, as shown in FIGS. 10 and 11 , the recess 63H is recessed deeper than the surface of the base 61 of the bearing holder 60 on the anti-load side. A capacitor 253 mounted on the first surface 21b of the circuit board 20 is inserted into the recess 63H of the bearing holder 60. A heat dissipation material TM is applied between the circuit board 20 and the bottom surface (third heat-receiving surface) of the recess 63H of the bearing holder 60. The heat dissipation material TM is, for example, a material obtained by mixing a thermally conductive filler with a silicone polymer, and is called a TIM (Thermal Interface Material). The heat dissipation material TM may be any material other than the above-mentioned materials, as long as it has a higher thermal conductivity than the board body 21 of the circuit board 20. An end of a second electronic component (e.g., a capacitor 253) other than the driving element 252 is inserted inside the recess 63H. Heat generated by the capacitor 253 is transmitted to the bearing holder 60 via the heat dissipation material TM, thereby suppressing heat generation by the capacitor 253.

[0071] As shown in Figure 11, shaft 31 is rotatably supported by bearing 33 and bearing 34. Bearing 33 is interposed between cylindrical portion 68 of flange portion 40 and shaft 31. Bearing 33 is disposed inside cylindrical portion 68. Bearing 34 is interposed between housing 930 and shaft 31. In this way, bearing holder 60 fixes the outer ring of bearing 33 inside cylindrical portion 68.

[0072] The lid 50 is made of metal and prevents foreign matter and moisture from entering the interior of the electric drive device 1. As shown in FIGS. 9 and 11 , the lid 50 has a top plate portion 55 and a support portion 52. As shown in FIG. 11 , the top plate portion 55 covers the circuit board 20. The support portion 52 is located radially outward of the top plate portion 55 and extends toward the flange portion 40 beyond the top plate portion 55, covering the side of the circuit board 20. The edge portion 51 is an end portion of the support portion 52 that faces the flange portion 40.

[0073] The top plate portion 55 has a first heat receiving surface 54 protruding toward the load side, a wall portion 53 surrounding the electronic components, and a storage portion 53R surrounded by the wall portion 53. The support portion 52 has a through hole 51H penetrating in the axial direction AX, and a bolt CT (see FIG. 7) is inserted into the through hole 51H.

[0074] 9 and 11, in order to dissipate heat generated by the circuit board 20, the first heat receiving surface 54 faces the circuit board 20. A heat dissipation material TM is applied between the drive element 252 of the circuit board 20 and the first heat receiving surface 54 of the lid 50. The heat generated by the drive element 252 is transmitted to the lid 50 via the heat dissipation material TM, thereby suppressing heat generation by the drive element 252.

[0075] 9 and 11, an end of the first electronic component (for example, capacitor 259) other than drive element 252 is inserted inside wall portion 53. As shown in FIG. 11, a heat dissipation material TM is applied between circuit board 20 and the bottom surface (second heat receiving surface) of storage portion 53R. Heat generated by capacitor 259 is transferred to lid body 50 via heat dissipation material TM, thereby suppressing heat generation by capacitor 259. For example, capacitor 259 is an electrolytic capacitor.

[0076] As shown in FIG. 8, the circuit board 20 includes a board body 21 and a plurality of electronic components mounted on the board body 21. The board body 21 is, for example, a printed circuit board made of resin or the like. The circuit board 20 is a multilayer board having a plurality of conductive layers provided therein, and is a double-sided mounting board that allows for double-sided mounting. The plurality of electronic components mounted on one board body 21 include, for example, a central processing unit (CPU), an application specific integrated circuit (ASIC), a field effect transistor (FET), a magnetic sensor, an electrolytic capacitor, a resistor, a diode, a thermistor, and the like. These plurality of electronic components form the detection circuit 23, the control circuit 24, the first power circuit 25A, and the second power circuit 25B shown in FIG. 5.

[0077] For example, as shown in Fig. 8, a plurality of drive elements 252, a first motor drive circuit 26A, a second motor drive circuit 26B, a capacitor 259, a choke coil 91, a capacitor 92, etc. are mounted on the anti-load side of circuit board 20. Capacitor 259 is connected to boost circuit 245 (Fig. 5) to form a switched capacitor circuit. Here, as shown in Fig. 11, the load side of circuit board 20 is first surface 21b (load side surface), and the anti-load side of circuit board 20 is second surface 21a (anti-load side surface).

[0078] The detection circuit 23, the control circuit 24, the first power circuit 25A, and the second power circuit 25B shown in Fig. 5 are configured with one or more electronic components mounted on the first surface 21b or the second surface 21a. For example, as shown in Fig. 11, the detection circuit 23 is configured with one electronic component mounted on the first surface 21b of the substrate main body 21.

[0079] 5 is configured with a plurality of electronic components mounted on the second surface 21a of the substrate body 21. As shown in FIG. 11, the circuit board 20 includes a capacitor 253 mounted on the second surface 21a of the substrate body 21.

[0080] The detection circuit 23 is disposed on the anti-load side of the shaft 31, on an extension of the axial direction AX of the magnet 32. The substrate body 21 has a plane perpendicular to the axial direction AX as its mounting surface for the detection circuit 23. The rotation angle sensor 23a (see FIG. 5) of the detection circuit 23 is mounted within the detection circuit 23 so as to be able to sense changes in the magnetic field of the magnet 32. It is desirable that the magnet 32 ​​and the rotation angle sensor 23a face each other in the axial direction AX. The rotation angle sensor 23a may be disposed on the second surface 21a instead of the first surface 21b of the substrate body 21, or may be disposed on both the first surface 21b and the second surface 21a of the substrate body 21.

[0081] The rotation angle sensor 23a is, for example, a spin valve sensor. A spin valve sensor is an element in which a non-magnetic layer is sandwiched between a pinned layer of a ferromagnetic material, the magnetization direction of which is fixed by an antiferromagnetic layer or the like, and a free layer of a ferromagnetic material, and is a sensor that can detect changes in the direction of magnetic flux. Spin valve sensors include GMR (Giant Magneto Resistance) sensors and TMR (Tunnel Magneto Resistance) sensors. Note that the rotation angle sensor 23a may be any sensor that can detect the rotation of the magnet 32. The rotation angle sensor 23a may be, for example, an AMR (Anisotropic Magneto Resistance) sensor or a Hall sensor.

[0082] As shown in FIG. 8, the electric drive device 1 includes first coil wiring 321 that connects the first coil group Gr1 (see FIG. 3) to the circuit board 20, and second coil wiring 322 that connects the second coil group Gr2 (see FIG. 3) to the circuit board 20. The first coil wiring 321 and the second coil wiring 322 may be included in the ECU 10 or may be included in the motor 30. The first coil wiring 321 and the second coil wiring 322 are inserted into through holes in the circuit board 20, and the circuit board 20 is electrically connected to the first coil wiring 321 and the second coil wiring 322. Note that the first coil wiring 321 and the second coil wiring 322 are omitted from FIG. 11.

[0083] As shown in Fig. 11, the motor 30 includes a housing 930. The motor rotor 932 includes a rotor yoke 932a and a magnet 932b. The magnet 932b is provided on the outer peripheral surface of the rotor yoke 932a. The housing 930 is cylindrical and accommodates therein the motor rotor 932, a stator including a plurality of coil groups divided into two systems for each three phase, for example, a first coil group Gr1 and a second coil group Gr2 (see Fig. 3), and the shaft 31.

[0084] As shown in Figures 10 and 11, a magnet 32 ​​is attached to one end of the shaft 31 via a magnet holder 32A. Half of the magnet 32 ​​is magnetized as a south pole when viewed from the axial direction AX, and the other half is magnetized as a north pole. Alternatively, the magnet 32 ​​may have south and north poles arranged alternately on its outer surface when viewed in the circumferential direction. Because the bearing 33 has high component precision, the position of the magnet 32, which is located on the anti-load side of the flange portion 40, in the axial direction AX is constant. The end where the magnet 32 ​​is located is the anti-load end of the shaft 31.

[0085] 11, the other end of the shaft 31 is provided with a motor gear 31G that transmits rotation to the worm shaft (see FIG. 2) of the reduction gear 175. The end of the shaft 31 at which the motor gear 31G is provided is the load side end of the shaft 31.

[0086] Fig. 11 is a cross-sectional view showing a cross section taken along the line XI-XI in Fig. 6. Fig. 12 is a cross-sectional view showing a partial cross section in which a portion Q1 in Fig. 11 is enlarged. Fig. 13 is a cross-sectional view showing a cross section taken along the line XII-XII in Fig. 6.

[0087] As shown in Fig. 11, when the lid 50 and the flange 40 are fitted together, the edge 51 is located radially outward of the protrusion 45. As shown in Fig. 12, the flange upper surface 41F and the edge lower surface 51F (second surface) of the edge 51 of the lid 50 face each other and are fixed together with a maximum distance 49D between them. The outer side surface 45S of the protrusion 45 and the inner side surface 51S of the edge 51 face each other and are fixed together with a maximum distance 45D between them. The maximum distance 45D is smaller than the maximum distance 49D.

[0088] As shown in Figure 13, the top of the position restricting portion 43 and the edge lower surface 51F (second surface) of the edge portion 51 of the lid 50 are in contact. The height from the flange upper surface 41F to the top of the position restricting portion 43 is a distance 43D. The outer side surface 45S of the protrusion 45 and the inner side surface 51S of the edge portion 51 face each other and are fixed in place while being separated by a maximum distance 45D. The distance 43D is the same as the maximum distance 49D.

[0089] When the bolt CT is fastened to the female thread 44, the cover 50 and the flange 40 are fixed together. This causes the top of the position restricting portion 43 to abut against the edge lower surface 51F, restricting the position of the edge lower surface 51F relative to the flange upper surface 41F. As a result, the distance 43D and the maximum distance 49D become approximately equal, and the maximum distance 49D tends to be constant around the flange 40.

[0090] 12 and 13, a foam-in-place gasket 49 is filled between the edge portion 51 and the flange portion 40. The foam-in-place gasket 49 is also called a liquid gasket, and is paste-like and shape-changeable when uncured, and when cured, it becomes elastic and its outer shape is fixed. The cured foam-in-place gasket 49 becomes a sealing material that is waterproof and dustproof against external moisture and dust.

[0091] As described above, the flange portion 40 has a base portion 41, a protruding portion 45, a flange upper surface 41F (first surface), a position restricting portion 43, and a groove portion 42. The base portion 41 is a portion that protrudes radially outward from the motor 30. The protruding portion 45 protrudes from the base portion 41 toward the anti-load side and continuously protrudes in an annular shape when viewed in the axial direction AX. The flange upper surface 41F is provided radially outward from the protruding portion 45 and faces the cover 50. The multiple position restricting portions 43 are island-shaped convex portions that protrude from the first surface on the flange upper surface 41F toward the anti-load side. The groove portion 42 is provided annularly along the protruding portion when viewed in the axial direction, and is provided between the flange upper surface 41F and the protruding portion 45 and between the position restricting portion 43 and the protruding portion 45, and is a portion that is recessed from the flange upper surface 41F.

[0092] The cover 50 has a top plate 55, a support portion 52, and an edge portion 51. The support portion 52 is radially outward of the top plate 55 and extends further toward the load side than the top plate 55. The edge portion 51 is radially outward of the protrusion 45. The edge portion 51 of the cover 50 has an edge lower surface 51F (second surface) facing the flange upper surface 41F and a radially inner edge side surface 51S facing the radially outer side surface 45S of the protrusion 45. The form-in-place gasket 49 seals the groove 42, the gap between the flange upper surface 41F and the edge lower surface 51F, and the gap between the outer side surface 45S of the protrusion 45 and the edge inner side surface 51S. The bolt CT fastens the edge portion 51 to the position restricting portion 43 with the edge lower surface 51F contacting the position restricting portion 43.

[0093] This makes it easy to fit the lid 50 onto the flange 40. Furthermore, the edge 51 of the lid 50 can be positioned relative to the flange 40 without the form-in-place gasket 49 easily coming into contact with the position restricting portion 43. As a result, the assembly work of attaching the lid 50 to the flange 40 is made easier, and the form-in-place gasket 49 provides waterproofing to the electric drive unit 1.

[0094] Fig. 14 is a cross-sectional view showing a cross section taken along arrows XIV-XIV in Fig. 8. Fig. 15 is a perspective view illustrating a connector according to embodiment 1. As shown in Fig. 15, connector CNT is inserted from the anti-load side of base 41 of flange 40 to the load side. As shown in Fig. 15, connector CNT has base 72, socket 71A, socket 71B, sealing pedestal 77, sealing wall 76, first reinforcing wall 73, second reinforcing wall 78, first reference pin P1, second reference pin P2, guide wall 75, first connector terminal PPW, second connector terminal PCN, and third connector terminal PTS.

[0095] 15, socket portion 71A and socket portion 71B protrude from base portion 72 toward the load side. A plug for wiring PW from power supply device 183 and a communication plug for CAN communication are inserted into socket portion 71A. A communication plug for transmitting steering torque signal T and the like is inserted into socket portion 71B.

[0096] 15, the base 72 has a reference plate 722 and an outer wall portion 721 that surrounds the outer edge of the reference plate 722 and extends to the anti-load side beyond the anti-load side surface of the reference plate 722. The reference plate 722 has four through holes 722H.

[0097] As shown in FIG. 15, the sealing seat 77 protrudes toward the anti-load side from the anti-load side surface of the reference plate 722, and has a flat surface on which a form-in-place gasket is applied.

[0098] 15, the sealing wall 76 is located above the sealing base 77 and protrudes further toward the anti-load side than the sealing base 77. The outer surface of the sealing wall 76 is at an angle of approximately 90 degrees to the anti-load side of the sealing base 77.

[0099] 15 , the first reinforcing wall 73 receives the first connector terminals PPW and the second connector terminals PCN and prevents the first connector terminals PPW and PCN from bending. The first reinforcing wall 73 is integrated with the sealing wall 76 on top of the sealing wall 76 and protrudes toward the anti-load side beyond the sealing wall 76 on the outer side of the first reinforcing wall 73. An opening 76H communicating with the interior of the socket portion 71A is formed on the inner side of the sealing wall 76, and the first connector terminals PPW and the second connector terminals PCN inserted into the opening 76H are attached to the first reinforcing wall 73. The interior of the opening 76H is preferably sealed with potting resin or the like to ensure waterproofing.

[0100] The guide wall 75 connects the first reinforcing wall 73 and the first reference pin P1. This allows the first reference pin P1 to be supported by the guide wall 75, and the guide wall 75 acts as a rib. As a result, bending of the first reference pin P1 is suppressed. The guide wall 75 is a wall that extends outward from the first reference pin P1, and its width does not change in the axial direction AX and is smaller than the width of the first reinforcing wall 73. The length of the guide wall 75 from the first reference pin P1 to the first reinforcing wall 73 becomes smaller toward the tip on the anti-load side. This makes it easier to insert the guide wall 75 into the slit 473H3.

[0101] As shown in Fig. 15, the third connector terminals PTS are fitted into the second reinforcing wall 78, which prevents the third connector terminals PTS from bending. The second reinforcing wall 78 is surrounded by a sealing base 77 and protrudes further toward the anti-load side than the sealing base 77. The height of the second reinforcing wall 78 from the anti-load side surface of the reference plate 722 is approximately the same as that of the first reinforcing wall 73. An opening 77H communicating with the interior of the socket portion 71B is provided near the second reinforcing wall 78, and the third connector terminals PTS inserted into the opening 77H are attached to the second reinforcing wall 78. The interior of the opening 77H is desirably sealed with potting resin or the like to ensure waterproofing.

[0102] 15, the height of the first reference pin P1 from the anti-load side surface of the reference plate 722 is greater than that of the second reference pin P2. The height of the first reference pin P1 from the anti-load side surface of the reference plate 722 is greater than that of the anti-load side tips of the first connector terminal PPW and the second connector terminal PCN. The height of the first reference pin P1 from the anti-load side surface of the reference plate 722 is greater than that of the guide wall 75 and the first reinforcing wall 73.

[0103] The base 72, socket 71A, socket 71B, sealing pedestal 77, sealing wall 76, first reinforcing wall 73, second reinforcing wall 78, first reference pin P1, and second reference pin P2 are integrally molded from a resin material of the connector CNT. The resin material of the connector CNT is, for example, polybutylene terephthalate (PBT). The first connector terminal PPW, second connector terminal PCN, and third connector terminal PTS are formed from a conductive metal such as copper.

[0104] 16 is a perspective view illustrating the anti-load side of the flange portion according to embodiment 1. Flange portion 40 has a first surface 471, a second surface 472, a third surface 479, a fourth surface 474, a fifth surface 475, and a groove 478 on a back surface 41R on the load side of base 41. Groove 478 surrounds first surface 471, second surface 472, third surface 479, fourth surface 474, and fifth surface 475 in a ring shape and is recessed toward the anti-load side with respect to back surface 41R.

[0105] The first surface 471 and the fourth surface 474 are flat surfaces that are located closer to the anti-load side than the back surface 41R and closer to the load side than the bottom of the groove 478. The second surface 472 is surrounded by the first surface 471 and is a flat surface that is located closer to the anti-load side than the back surface 41R, the bottom of the groove 478, and the first surface 471. The fifth surface 475 is surrounded by the fourth surface 474 and is a flat surface that is located closer to the anti-load side than the back surface 41R, the bottom of the groove 478, and the fourth surface 474.

[0106] Four female thread portions 479H1 are provided on the base 41 of the flange portion 40. Bolts BT3, which are fixing members shown in Fig. 12, pass through the through holes 722H (Fig. 15) and are fastened to the female thread portions 479H1 shown in Fig. 16, thereby fixing the flange portion 40 and the connector CNT.

[0107] 16, the second surface 472 has a second through hole 473H2 and a third through hole 473H1 that penetrate in the axial direction AX. The second through hole 473H2 and the third through hole 473H1 are connected by a slit 473H3. The third through hole 473H1 is rectangular when viewed in the axial direction AX. The second through hole 473H2 is circular when viewed in the axial direction.

[0108] A fixing hole 479H2 is provided in the third surface 479. A second reference pin P2 (see FIG. 15) is inserted into the fixing hole 479H2. The fixing hole 479H2 is a recess, but may also be a through-hole.

[0109] As shown in FIG. 16, the fifth surface 475 has a fourth through-hole 475H penetrating in the axial direction AX.

[0110] Fig. 17 is a perspective view illustrating an assembly operation of the connector according to the first embodiment. Fig. 18 is a perspective view illustrating an assembly operation of the connector according to the first embodiment. The connector shown in Fig. 18 is moved closer to the flange portion 40 than the connector shown in Fig. 17. As shown in Fig. 17, the flange portion 40 has a first upper surface 461 around the second through hole 473H2, the third through hole 473H1, and the slit 473H3. The flange portion 40 has a second upper surface 462 around the fourth through hole 475H. The first upper surface 461 and the second upper surface 462 are approximately the same height.

[0111] As shown in FIG. 17, when the connector CNT is inserted into the flange portion 40 from the load side, first, the first reference pin P1 is inserted into the second through-hole 473H2.

[0112] 18, the guide wall 75 is inserted into the slit 473H3. As a result, the position and posture of the connector CNT relative to the flange portion 40 are restricted by the first reference pin P1 and the guide wall 75, making it easier to insert the connector CNT parallel to the axial direction AX into the flange portion 40. Then, the first connector terminal PPW and the second connector terminal PCN are inserted into the third through hole 473H1. Also, the third connector terminal PTS is inserted into the fourth through hole 475H.

[0113] Furthermore, when the connector CNT approaches the flange portion 40, the second reference pin P2 shown in FIG. 15 is inserted into the fixing hole 479H2. As shown in FIG. 14, the first reference pin has a tapered portion 74 whose diameter decreases toward the tip. This allows the circuit board 20 to rotate around the first reference pin P1 when the tip of the first reference pin P1 is inserted into the through hole of the circuit board 20 and the first connector terminal PPW, the second connector terminal PCN, and the third connector terminal PTS are not connected to the circuit board. When the inner side of the second through hole 473H2 abuts against the tapered portion 74, the second reference pin P2 is easily inserted into the fixing hole 479H2. As a result, the positional relationship of the connector CNT with respect to the flange portion 40 is regulated by the first reference pin P1 and the second reference pin P2.

[0114] 14, there is a gap between the flange portion 40 and the connector CNT, which is filled with a form-in-place gasket 79. The first reference pin P1 and the second reference pin P2 regulate the positional relationship of the connector CNT with respect to the flange portion 40, so that the gap filled with the form-in-place gasket 79 can be stably formed.

[0115] Next, the first through-hole 20H of the circuit board 20 is aligned with the first reference pin P1, and the circuit board 20 is pushed down so that the first reference pin P1 penetrates deeply. This inserts the first reference pin P1 into the first through-hole 20H of the circuit board 20. The first reference pin P1 has a tapered portion 74. Therefore, when the tip of the first reference pin P1 is inserted into the first through-hole 20H of the circuit board 20 and the first connector terminal PPW is not connected to the circuit board 20, the circuit board 20 can rotate around the first reference pin P1 in the direction TF1, as shown in FIG. 8 . When the first reference pin P1 is inserted into the first through-hole 20H of the circuit board 20 and the circuit board 20 is at a height that allows it to rotate, the protrusion 60L shown in FIGS. 8 and 17 has a height that allows the abutment portion 20L, a part of the end face of the circuit board 20, to abut against the protrusion 60L. The protrusion 60L shown in FIGS. 8 and 17 is located on the opposite side of the first reference pin P1 with respect to the reference point obtained by extending the shaft 31 in the axial direction AX. The circuit board 20 is positioned with respect to the motor 30 and the connector CNT by the area AP1 where the first reference pin P1 is located and the abutment portion 20L that abuts against the protrusion 60L. As a result, when the circuit board 20 is pressed down in the load side direction TF2, the first connector terminals PPW are fitted into the holes in the first connection area APW of the circuit board 20. Similarly, the second connector terminals PCN are fitted into the holes in the second connection area ACN of the circuit board 20. Furthermore, the third connector terminals PTS are fitted into the holes in the third connection area ATS of the circuit board 20.

[0116] As described above, the electric drive device 1 according to the first embodiment includes the motor 30 and the ECU 10 provided on the anti-load side of the shaft 31 for driving and controlling the motor 30. The ECU 10 includes the magnet 32 ​​at the end of the shaft 31 on the anti-load side, and the circuit board 20 arranged on the anti-load side of the shaft 31, on an extension of the axial direction of the shaft 31 (for example, the axial direction AX). The circuit board 20 has a detection circuit 23 including a rotation angle sensor 23a that detects the rotation of the magnet 32. The rotation angle sensor 23a is a magnetic sensor that detects the rotation of the magnet 32.

[0117] The ECU 10 includes a circuit board 20 and a connector CNT. The connector CNT has a first connector terminal PPW that protrudes from a base of the connector CNT toward the anti-load side and connects to the circuit board 20, and a first reference pin P1 that protrudes from the base of the connector CNT toward the anti-load side, has a tip that is located on the anti-load side of the first connector terminal PPW, the second connector terminal PCN, and the third connector terminal PTS, and has a tip that is inserted into a first through-hole 20H of the circuit board 20. The motor 30 has a protrusion 60L that protrudes from the load side to the anti-load side to a height that allows a butting portion 20L, which is a part of the end face of the circuit board 20, to abut against when the tip of the first reference pin P1 is inserted into the first through-hole 20H of the circuit board 20 and the first connector terminal PPW is not connected to the circuit board 20.

[0118] This allows the circuit board 20 to be aligned with the first reference pin P1 and simply inserted into the first through-hole 20H of the circuit board 20. The abutment portion 20L of the circuit board 20 is aligned with the protrusion 60L of the motor 30. This regulates not only the relative positional relationship between the connector CNT and the circuit board 20 but also the relative positional relationship between the housing 930 of the motor 30 and the circuit board 20. As a result, simply moving the positioned circuit board 20 in the load-side direction FT2 not only determines the positional relationship between the circuit board 20 and the first connector terminals PPW, but also determines the fixed position of the circuit board 20 relative to the housing 930 of the motor 30. As a result, the first connector terminals PPW can be positioned relative to the circuit board 20 and the housing 930 while improving the assembly workability of the connector CNT. Similarly, the second connector terminals PCN and the third connector terminals PTS can be positioned relative to the circuit board 20 and the housing 930.

[0119] Moreover, the electric power steering device 100 includes the electric drive unit 1 described above, and the electric drive unit 1 generates an auxiliary steering torque.

[0120] (Embodiment 2) 19 is a schematic diagram of an electric power steering device according to embodiment 2. Note that the same components as those described in the above-mentioned embodiment 1 and embodiment 2 are given the same reference numerals, and redundant description will be omitted.

[0121] As shown in Fig. 19, the electric power steering device 100A is of a rack-parallel type. The shaft 31 of the motor 30 is connected to a power transmission mechanism 173. The power transmission mechanism 173 has a pulley 176 and a belt 177. The rotation of the belt 177 rotates a nut of a ball screw device 178. As a result, an assist force is applied to the rack shaft 199C based on the rotation of the shaft 31 of the motor 30.

[0122] (Embodiment 3) Fig. 20 is a schematic diagram of an electric power steering device according to a third embodiment. Note that the same components as those described in the first and second embodiments above are assigned the same reference numerals, and redundant description will be omitted. The electric power steering device 100B shown in Fig. 20 is of a pinion assist type that applies an assist steering torque to a first pinion shaft 199A. In the electric power steering device 100B, a torque sensor 194 is connected to the first pinion shaft 199A.

[0123] The motor 30 rotates the worm shaft reduction gear 175. The worm wheel of the reduction gear 175 rotates integrally with the first pinion shaft 199A. This allows the motor 30 to rotate the first pinion gear 199B. The first pinion gear 199B meshes with the first rack 199D. As a result, the electric drive unit 1 applies an assist force to the first rack 199D via the reduction gear 175. The first pinion gear 199B may be disposed orthogonal to the first rack 199D, or may be disposed obliquely away from the orthogonal orientation. As described above, the electric power steering device 100B of the third embodiment is of a single-pinion assist type.

[0124] (Embodiment 4) Fig. 21 is a schematic diagram of an electric power steering device according to a fourth embodiment. Note that the same components as those described in the first to third embodiments are assigned the same reference numerals, and redundant description will be omitted. The electric power steering device 100C includes an output shaft 192B and a second pinion gear 171B in addition to a first pinion shaft 199A and a first pinion gear 199B. The electric power steering device 100C is of a dual pinion assist type. A torque sensor 194 detects the torque between a pinion shaft 195 and a first pinion gear 199B.

[0125] The motor 30 rotates the reduction gear 175 of the worm shaft. The worm wheel of the reduction gear 175 rotates integrally with the output shaft 192B. This allows the motor 30 to rotate the second pinion gear 171B. The second pinion gear 171B meshes with the second rack 171C. As a result, the electric drive unit 1 applies an assist force to the second rack 171C via the reduction gear 175. The second pinion gear 171B may be disposed orthogonal to the second rack 171C, or may be disposed obliquely away from the orthogonal orientation. The electric power steering device 100C of the fourth embodiment is of a dual pinion assist type. [Explanation of symbols]

[0126] 1 Electric drive unit 10 ECU 20 Circuit Board 20H 1st through hole 20L Stop part 21 Board body 21a 2nd side 21b 1st page 23 Detection circuit 24 Control circuit 25A 1st power circuit 25B Second power circuit 30 motor 31 Shaft 32 Magnet 37 First coil 38 Second coil 40 flange 41 Base 41F Flange top surface 42 Groove 43 Position regulation part 44 Female thread 45 Protrusion 473H 2nd through hole 473H1 3rd through hole 473H2 2nd through hole 473H3 Slit 479H2 fixing hole 49, 79 Foam-in-place gasket 50 Lid 51 Edge 52 Support part 53 Wall 53R storage section 54 1st heat receiving surface 55 Top plate 60 bearing holder 60L convex part 61 Base 63H recess 100, 100A, 100B, 100C Electric power steering device 251 Inverter Circuit 252 driving element 253, 259 capacitors 930 Housing 931 stator core 932 Motor rotor P1 First reference pin P2 Second reference pin CNT Connector

Claims

1. An electric drive device comprising a motor and an electronic control device that controls the rotation of the motor, The motor a shaft extending axially from a load side to a non-load side; a motor rotor coupled to the shaft; a motor stator that rotates the motor rotor; a housing that accommodates the motor rotor and the motor stator therein; a flange portion provided on the anti-load side of the housing; Including, The electronic control device A circuit board; a connector fixed to the flange portion and connected to the circuit board; Including, The connector comprises: a first connector terminal protruding from a base portion of the connector toward the anti-load side and connected to the circuit board; a first reference pin that protrudes from a base portion of the connector toward the anti-load side, has a tip that is located on the anti-load side of the first connector terminal, and is inserted into a first through-hole of the circuit board; and The motor a protrusion protruding from the load side to the anti-load side at a height that allows a butting portion of an end surface of the circuit board to come into contact with the protrusion when the tip of the first reference pin is inserted into the first through-hole of the circuit board and the first connector terminal is not connected to the circuit board; Electric drive unit.

2. The first reference pin has a tapered portion whose diameter decreases toward the tip. The electric drive device according to claim 1 .

3. the flange portion includes a base portion of the flange portion, a second through-hole penetrating the base portion of the flange portion, and a slit penetrating the base portion of the flange portion and extending outward from the second through-hole, The connector comprises: a guide wall extending outward from the first reference pin; the first reference pin is inserted into the second through hole, and the guide wall is inserted into the slit; The electric drive device according to claim 1 .

4. the flange portion includes a third through-hole that penetrates a base portion of the flange portion, The connector comprises: a first reinforcing wall into which the first connector terminal is fitted; the guide wall connects the first reinforcing wall and the first reference pin; The electric drive device according to claim 3 .

5. The flange portion is a fixing hole provided on the anti-load side of the base, The connector comprises: a second reference pin protruding from the base of the connector toward the anti-load side and having a tip located on the anti-load side relative to the tip of the first reference pin; The second reference pin is inserted into the fixing hole.

5. The electric drive device according to claim 4.

6. Between the flange portion and the connector, there is a gap filled with a form-in-place gasket.

5. The electric drive device according to claim 4.

7. The electric drive device according to any one of claims 1 to 5, the electric drive unit generates an auxiliary steering torque; Electric power steering device.

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