Electrical unit

Abstract

This technology provides a way to minimize the size increase of a housing that contains a terminal block. [Solution] The electrical unit comprises a housing in which a service hole is formed, and a terminal block housed within the housing. The housing has a rib that crosses the opening of the service hole. The terminal block has a first electrical connection structure and a second electrical connection structure of a different type from the first electrical connection structure. At least a portion of the first electrical connection structure is positioned to be exposed to the outside through the opening of the service hole. At least a portion of the second electrical connection structure is positioned on the back of the rib.

Description

Technical Field

[0001] The technology disclosed in this specification relates to an electric unit.

Background Art

[0002] An electric unit in which electric components are housed in a housing is known. An electric unit in which mechanical components are also housed in the housing is particularly called an electromechanical integrated unit, and its development is underway. Patent Document 1 discloses an example of this type of electric unit.

[0003] In the housing, a terminal block for ensuring electrical connection between these components is provided. The terminal block is arranged at a position exposed to the outside from the opening of the service hole. Thereby, after assembling the components in the housing, the operator can access the terminal block through the opening of the service hole and perform operations for electrical connection at the terminal block.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] Electrical connection structures corresponding to the components housed within the housing are sometimes integrated into the terminal block. Examples of such electrical connection structures are not limited to those mentioned above, but include connection structures that fasten conductor plates together with fasteners, and connection structures that connect wire harnesses together with intermediate connectors. When multiple types of such electrical connection structures are provided on the terminal block, the size of the terminal block increases. To minimize the increase in housing size, a technology is needed to accommodate the terminal block within the limited space of the housing. This specification provides a technology that can minimize the increase in housing size in a housing that accommodates a terminal block. [Means for solving the problem]

[0006] An electrical unit disclosed herein may comprise a housing having a service hole formed therein, and a terminal block housed within the housing. The housing may have a rib traversing the opening of the service hole. The terminal block may comprise a first electrical connection structure and a second electrical connection structure of a different type from the first electrical connection structure. At least a portion of the first electrical connection structure may be positioned to be exposed to the outside through the opening of the service hole. At least a portion of the second electrical connection structure may be positioned on the back of the rib. The first electrical connection structure may be of a type that requires work for electrical connection between components through the opening of the service hole after the components have been assembled in the housing, for example. The second electrical connection structure may be of a type that does not require work for electrical connection between components through the opening of the service hole after the components have been assembled in the housing, for example. The housing of the electrical unit described above has the rib traversing the service hole in order to suppress a decrease in the rigidity of the housing. When such ribs are provided in the service hole, it is difficult for workers to access the back of the ribs through the opening in the service hole. In the electrical unit described above, an electrical connection structure of a type that does not interfere with electrical connection work even when placed on the back of the rib may be placed on the back of the rib. Therefore, the space on the back of the rib formed in the service hole can be effectively utilized, making it possible to suppress the enlargement of the housing. [Brief explanation of the drawing]

[0007] [Figure 1] An end view schematically showing the configuration of the electromechanical unit 10. [Figure 2] A diagram showing the configuration of the terminal block 40 as seen through the opening of the service hole 14f. [Figure 3] End view corresponding to line III-III in Figure 1. [Figure 4]End view corresponding to line IV-IV in Figure 1. [Modes for carrying out the invention]

[0008] The following describes an example of an electrical unit, the electromechanical unit 10, with reference to Figures 1 to 4. The electromechanical unit 10 is not particularly limited, but may be mounted, for example, in the front compartment of an electric vehicle. The electric vehicle referred to here may be a hybrid vehicle driven by an engine and a motor, or an electric vehicle or fuel-powered vehicle driven by a motor.

[0009] Here, each direction of the electromechanical unit 10 in the drawing is defined by the direction when mounted on an electric vehicle, i.e., the direction of the electric vehicle. Therefore, direction FR indicates the front in the longitudinal direction of the electric vehicle, and direction RR indicates the rear in the longitudinal direction of the electric vehicle. Direction LH indicates the left in the lateral direction of the electric vehicle, and direction RH indicates the right in the lateral direction of the electric vehicle. Direction UP indicates the upward direction in the vertical direction of the electric vehicle, and direction DW indicates the downward direction in the vertical direction of the electric vehicle.

[0010] As shown in Figure 1, the electromechanical unit 10 comprises a housing 12, a power control circuit 20, a control board 30, a terminal block 40, a plurality of motors 50, 52, a gear mechanism 54, and a plurality of sensors 60, 62.

[0011] The housing 12, which is a casing component, comprises a housing body 14 and a cover plate 16. The housing body 14 has a bottom wall 14a and a peripheral wall 14b extending upward from the outer edge of the bottom wall 14a. An opening 14c is formed at the top of the housing body 14, defined by the upper end of the peripheral wall 14b. The opening 14c of the housing body 14 is closed by the cover plate 16. The cover plate 16 is detachable from the opening 14c of the housing body 14. A power control circuit 20 is fixed to the lower surface of the cover plate 16, and a control board 30 is fixed to the upper surface of the cover plate 16. The control board 30 is covered by a protective cover 18 provided on the cover plate 16. A power socket 17 is provided on the part of the cover plate 16 that is not covered by the protective cover 18. A power connector 6 of the power cable 4 can be connected to the power socket 17. This allows DC power output from a power source mounted on the electric vehicle to be supplied to the power control circuit 20. The housing body 14, cover plate 16, and protective cover 18 are not particularly limited, but may be made of a conductive material such as aluminum.

[0012] The housing 12 further has a partition wall 14d that divides the internal space of the housing 12 vertically. The internal space of the housing 12 below the partition wall 14d is called the first room R1, and the internal space of the housing 12 above the partition wall 14d is called the second room R2.

[0013] The first chamber R1 of the housing 12 is provided with a plurality of motors 50, 52, a gear mechanism 54, and a plurality of sensors 60, 62. The plurality of motors 50, 52 are driving motors that drive the wheels of the electric vehicle, and include a first motor 50 and a second motor 52. The gear mechanism 54 includes, for example, a planetary gear mechanism, a reduction gear mechanism, and a differential gear mechanism. The power from the plurality of motors 50, 52 is output to the wheels of the electric vehicle via the gear mechanism 54.

[0014] The first motor 50 is a three-phase AC motor and has three motor terminals m1 to m3 corresponding to the U-phase, V-phase, and W-phase. Similarly, the second motor 52 is also a three-phase AC motor and has three motor terminals m4 to m6 corresponding to the U-phase, V-phase, and W-phase. These motor terminals m1 to m6 are elongated conductive plates and may be made of a conductive material such as metal, although this is not particularly limited. The multiple motor terminals m1 to m6 are housed in the first chamber R1 of the housing 12. Each of the multiple motor terminals m1 to m6 extends upward toward the electric vehicle and is spaced apart from each other along the longitudinal direction of the electric vehicle. The space between motor terminal m3 and motor terminal m4 is wider than the other spacings.

[0015] The multiple sensors 60 and 62 include a first sensor 60 and a second sensor 62. The first sensor 60 is mounted on the first motor 50 and is a sensor that detects the state of the first motor 50. The first sensor 60 is not particularly limited, but for example, it may be at least one of a rotation angle sensor that detects the rotation angle of the first motor 50 and a temperature sensor that detects the temperature of the first motor 50. The wire harness 64 connected to the first sensor 60 is connected to the relay connector 44 of the terminal block 40, as will be described later. The second sensor 62 is mounted on the second motor 52 and is a sensor that detects the state of the second motor 52. The second sensor 62 is not particularly limited, but for example, it may be at least one of a rotation angle sensor that detects the rotation angle of the second motor 52 and a temperature sensor that detects the temperature of the second motor 52. The wire harness 66 connected to the second sensor 62 is connected to the relay connector 44 of the terminal block 40, as will be described later.

[0016] A power control circuit 20 is provided in the second chamber R2 of the housing 12. The power control circuit 20 has a boost converter and an inverter, and boosts the DC power supplied from the power source and converts it into AC power. A power control terminal block 22 is provided adjacent to the power control circuit 20. The power control terminal block 22 has power control terminals y1 to y6 for outputting the AC power generated by the power control circuit 20. These power control terminals y1 to y6 are elongated conductive plates and are not particularly limited, but may be made of a conductive material such as metal. Three power control terminals y1 to y3 corresponding to the U phase, V phase, and W phase are power control terminals for outputting AC power to the first motor 50. Three power control terminals y4 to y6 corresponding to the U phase, V phase, and W phase are power control terminals for outputting AC power to the second motor 52. The multiple power control terminals y1 to y6 are housed in the second chamber R2 of the housing 12. Each of the multiple power control terminals y1 to y6 extends downward from the electric vehicle and is spaced apart from one another along the longitudinal direction of the electric vehicle. The spacing between power control terminal y3 and power control terminal y4 is wider than the other spacings.

[0017] The control board 30, located on the upper surface of the cover plate 16, includes a microcomputer with, for example, a CPU, RAM, ROM, and an input / output interface. The control board 30 controls the operation of the power control circuit 20 by having the CPU perform signal processing in a work area reserved on the RAM according to a program stored in the ROM. In this process, the control board 30 controls the operation of the power control circuit 20 by referring to detection signals from various sensors, including a plurality of sensors 60 and 62.

[0018] A through-hole 14e is formed in the partition wall 14d of the housing 12, penetrating between the first chamber R1 and the second chamber R2. The terminal block 40 is installed to close the through-hole 14e in the partition wall 14d and is positioned across the first chamber R1 and the second chamber R2.

[0019] The terminal block 40 comprises a terminal block body 42, a plurality of relay bus bars b1 to b6, and a relay connector 44. The terminal block body 42 is generally box-shaped and is not particularly limited, but may be made of an insulating material such as resin. The plurality of relay bus bars b1 to b6 are elongated conductive plates fixed to the terminal block body 42 and are not particularly limited, but may be made of a conductive material such as metal. Each of the plurality of relay bus bars b1 to b6 may be integrally molded with a corresponding motor terminal from a plurality of motor terminals m1 to m6. That is, each of the plurality of relay bus bars b1 to b6 may be the tip of a corresponding motor terminal. For example, relay bus bar b1 may be the tip of motor terminal m1. The plurality of relay bus bars b1 to b6 extend along the vertical direction of the electric vehicle and are arranged at intervals from each other along the front-rear direction of the electric vehicle. The distance between relay busbar b3 and relay busbar b4 is wider than the other distances, and a relay connector 44 is provided between relay busbar b3 and relay busbar b4.

[0020] As shown in FIGS. 1 and 3, each of the plurality of relay busbars b1 to b6 extends across the first chamber R1 and the second chamber R2. Each of the plurality of relay busbars b1 to b6 is fastened to a corresponding motor terminal among the plurality of motor terminals m1 to m6 by a fastener 82 (for example, a bolt and a nut) in the first chamber R1. Thereby, each of the plurality of relay busbars b1 to b6 is electrically connected to a corresponding motor terminal. Each of the plurality of relay busbars b1 to b6 is fastened to a corresponding power control terminal among the plurality of power control terminals y1 to y6 by a fastener 84 (for example, a bolt and a nut) in the second chamber R2. Thereby, each of the plurality of relay busbars b1 to b6 is electrically connected to a corresponding power control terminal. In this specification, the electrical connection structure portion of the terminal block 40 that electrically connects the motor terminals m1 to m6, the relay busbars b1 to b6, and the power control terminals y1 to y6 is referred to as the "first electrical connection structure portion 72". That is, the first electrical connection structure portion 72 is an electrical connection structure portion that electrically connects between conductor plates by fastening the conductor plates with a fastener. Therefore, the first electrical connection structure portion 72 can transmit the high voltage required to drive the first motor 50 and the second motor 52.

[0021] As shown in Figures 1 and 4, the relay connector 44 is integrally molded with the terminal block body 42 of the terminal block 40. The relay connector 44 extends across the first chamber R1 and the second chamber R2, and has a plurality of first sockets 46 provided in the first chamber R1 and a second socket 48 provided in the second chamber R2. In Figure 4, for the purpose of clarity of illustration, only one of the plurality of first sockets 46 is shown. The plurality of first sockets 46 and the second socket 48 may be unevenly distributed in either the first chamber R1 or the second chamber R2. The plurality of first sockets 46 of the relay connector 44 are connected to the connectors at the ends of the wire harness 64 connected to the first sensor 60 and the connector at the end of the wire harness 66 connected to the second sensor 62. The second socket 48 of the relay connector 44 is connected to the connector at the end of the wire harness 32. The wire harness 32 extends within the first chamber R1 and is connected to the control board 30. Thus, the relay connector 44 relays the wire harnesses 64 and 66 extending from each of the multiple sensors 60 and 62 and the wire harness 32 extending from the control board 30, and transmits the detection signals detected by each of the multiple sensors 60 and 62 to the control board 30. In this specification, the electrical connection structure of the terminal block 40 that electrically connects the wire harnesses 64 and 66 extending from the multiple sensors 60 and 62 to the relay connector 44 and the wire harness 32 extending from the control board 30 is referred to as the "second electrical connection structure 74". That is, the second electrical connection structure 74 is an electrical connection structure that connects the wire harnesses with a relay connector. For this reason, the voltage transmitted through the second electrical connection structure 74 is lower than the voltage transmitted through the first electrical connection structure 72.

[0022] As shown in FIG. 2, a service hole 14f extending in the longitudinal direction of the electric vehicle is formed in the second chamber R2 of the housing 12. The housing 12 further has a rib 14g extending in the vertical direction of the electric vehicle and crossing the service hole 14f. When such a rib 14g is provided in the service hole 14f, a decrease in the rigidity of the housing 12 caused by forming the service hole 14f can be suppressed. Note that the shape of the rib 14g, including the width of the rib 14g in the longitudinal direction of the electric vehicle and the thickness of the rib in the left-right direction of the electric vehicle, can adopt various shapes. The service hole 14f is covered by a service hole cover 19 (see FIGS. 3 and 4) that covers the entire opening of the service hole 14f. The service hole cover 19 is detachably attached to the service hole 14f or is attached to the service hole 14f so as to be able to open and close the opening of the service hole 14f.

[0023] As shown in FIG. 2, a part of the first electrical connection structure portion 72, that is, a location where a plurality of power control terminals y1 to y6 and a plurality of relay bus bars b1 to b6 are fastened by a fastener 84, is arranged at a position exposed to the outside through the opening of the service hole 14f. In other words, when viewed from a direction orthogonal to the opening surface of the opening of the service hole 14f, a location where a plurality of power control terminals y1 to y6 and a plurality of relay bus bars b1 to b6 are fastened by a fastener 84 is not arranged at a position overlapping with the rib 14g. Thereby, after assembling various components in the housing 12, an operator can access the first electrical connection structure portion 72 of the terminal block 40 through the opening of the service hole 14f, and can perform an operation of fastening a plurality of power control terminals y1 to y6 and a plurality of relay bus bars b1 to b6 with a fastener 84.

[0024] As shown in Figure 2, a part of the second electrical connection structure 74, namely the relay connector 44, is located on the back of the rib 14g that crosses the service hole 14f. In other words, when viewed from a direction perpendicular to the opening surface of the opening of the service hole 14f, the relay connector 44 is located in a position that overlaps with the rib 14g. If the rib 14g is provided in the service hole 14f, it is difficult for an operator to access the back of the rib 14g through the opening of the service hole 14f. However, the wire harnesses 64 and 66 extending from each of the multiple sensors 60 and 62, and the wire harness 32 extending from the control board 30, are flexible and of sufficient length. Therefore, these wire harnesses 32, 64, and 66 can be connected to the relay connector 44 before assembling the various components into the housing 12. That is, the work of connecting the wire harnesses 32, 64, and 66 to the relay connector 44 does not need to be done through the opening of the service hole 14f.

[0025] In the electromechanical unit 10 described above, a relay connector 44, which does not require any work for electrical connection, is located on the back of the rib 14g through the opening of the service hole 14f. Therefore, the space on the back of the rib 14g formed in the service hole 14f can be effectively utilized, making it possible to suppress the enlargement of the housing 12.

[0026] The embodiments disclosed herein are summarized below. Note that the technical elements described below are independent technical elements that exhibit technical usefulness individually or in various combinations.

[0027] (Aspect 1) The electrical unit comprises a housing having a service hole formed therein, and a terminal block housed within the housing. The housing has a rib that crosses the opening of the service hole. The terminal block has a first electrical connection structure and a second electrical connection structure of a different type from the first electrical connection structure. At least a portion of the first electrical connection structure is positioned to be exposed to the outside through the opening of the service hole. At least a portion of the second electrical connection structure is positioned on the back of the rib.

[0028] (Aspect 2) In the electrical unit of embodiment 1, the opening of the service hole extends in one direction when viewed from a direction perpendicular to the opening surface of the opening of the service hole. The rib extends in a direction perpendicular to the one direction and crosses the opening.

[0029] (Aspect 3) In embodiment 1 or 2, at least a portion of the second electrical connection structure is positioned to overlap with the rib when viewed from a direction perpendicular to the opening surface of the opening of the service hole.

[0030] (Aspect 4) In any one of embodiments 1 to 3, the housing further comprises a partition wall located between a first chamber and a second chamber. The terminal block is arranged across the first chamber and the second chamber, passing through the partition wall.

[0031] (Appendix 5) In embodiment 4, the first electrical connection structure electrically connects the components provided in the first chamber and the second chamber, respectively. The second electrical connection structure electrically connects the components provided in the first chamber and the second chamber, respectively. The voltage transmitted through the second electrical connection structure is lower than the voltage transmitted through the first electrical connection structure.

[0032] (Aspect 6) In embodiment 5, the first electrical connection structure is an electrical connection structure that electrically connects conductor plates by fastening them together with fasteners. The second electrical connection structure is an electrical connection structure that electrically connects wire harnesses by connecting them together with relay connectors.

[0033] (Aspect 7) Any one of embodiments 1 to 6 further comprises a motor housed in the housing, a sensor housed in the housing for detecting the state of the motor, a power control circuit housed in the housing, and a control board for controlling the power control circuit. The motor and the power control circuit are electrically connected via the first electrical connection structure. The sensor and the control board are electrically connected via the second electrical connection structure.

[0034] (Pattern 8) In embodiment 7, the second electrical connection structure has a relay connector. The sensor is electrically connected to the relay connector via a first wire harness. The control board is electrically connected to the relay connector via a second wire harness.

[0035] (Aspect 9) The embodiment of embodiment 7 or embodiment 8 further comprises a power control terminal housed in the housing and electrically connected to the power control circuit. The power control terminal is fastened to the first electrical connection structure by a fastener. The fastening point between the power control terminal and the first electrical connection structure is positioned so as to be exposed to the outside through the opening of the service hole.

[0036] (Aspect 10) In any one embodiment of aspects 7 to 9, the housing further comprises a partition wall located between a first chamber and a second chamber. The terminal block is arranged across the first chamber and the second chamber, passing through the partition wall.

[0037] (Aspect 11) In embodiment 10, the motor and the sensor are housed in the first chamber of the housing. The power control circuit is housed in the second chamber of the housing.

[0038] (Aspect 12) In embodiment 11, the first electrical connection structure is electrically connected to the power control circuit in the second chamber.

[0039] (Aspect 13) Embodiment 12 further comprises a power control terminal housed in the housing and electrically connected to the power control circuit. The first electrical connection structure has a conductive plate that extends across the first and second chambers and is electrically connected to the motor. The power control terminal is fastened to the conductive plate of the first electrical connection structure by fasteners. The fastening point between the power control terminal and the conductive plate of the first electrical connection structure is positioned to be exposed to the outside through the opening of the service hole.

[0040] (Aspect 14) In any one of embodiments 11 to 13, the second electrical connection structure is electrically connected to the sensor in the first chamber and electrically connected to the control board in the second chamber.

[0041] The specific examples of the technology disclosed in this specification have been described in detail above, but these are merely illustrative and do not limit the scope of the claims. The technology described in the claims includes various modifications and changes to the specific examples described above. The technical elements described in this specification or in the drawings exhibit technical usefulness individually or in various combinations, and are not limited to the combinations described in the claims at the time of filing. The technology illustrated in this specification or in the drawings can achieve multiple objectives simultaneously, and achieving even one of these objectives itself constitutes technical usefulness. [Explanation of Symbols]

[0042] 10: Mechatronics unit, 12: Housing, 4f: Service hole, 14g: Rib, 40: Terminal block, 42: Terminal block body, 44: Relay connector, 72: First electrical connection structure, 74: Second electrical connection structure, b1~b6: Relay busbar, m1~m6: Motor terminals, y1~y6: Power control terminals

Claims

1. A housing with a service hole formed therein, The housing includes a terminal block, The aforementioned housing is It has a rib that crosses the opening of the service hole, The aforementioned terminal block is First electrical connection structure, It has a second electrical connection structure of a different type from the first electrical connection structure, At least a portion of the first electrical connection structure is positioned so as to be exposed to the outside through the opening of the service hole. At least a portion of the second electrical connection structure is an electrical unit located on the back of the rib.

2. The opening of the service hole extends in one direction when viewed from a direction perpendicular to the opening surface of the opening of the service hole. The electrical unit according to claim 1, wherein the rib extends in a direction perpendicular to the one direction and crosses the opening.

3. The electrical unit according to claim 1, wherein at least a portion of the second electrical connection structure is positioned to overlap with the rib when viewed from a direction perpendicular to the opening surface of the opening of the service hole.

4. The housing further includes a partition wall located between the first room and the second room. The electrical unit according to claim 1, wherein the terminal block is arranged across the first chamber and the second chamber, passing through the partition wall.

5. The first electrical connection structure electrically connects the components provided in the first chamber and the second chamber, The second electrical connection structure electrically connects the components provided in the first chamber and the second chamber, The electrical unit according to claim 4, wherein the voltage transmitted through the second electrical connection structure is lower than the voltage transmitted through the first electrical connection structure.

6. The first electrical connection structure is an electrical connection structure that electrically connects conductor plates by fastening them together with fasteners. The electrical unit according to claim 5, wherein the second electrical connection structure is an electrical connection structure that electrically connects wire harnesses by connecting them with relay connectors.

7. The motor housed in the aforementioned housing, A sensor housed in the aforementioned housing and used to detect the state of the motor, The power control circuit housed in the aforementioned housing, The system further includes a control board for controlling the aforementioned power control circuit, The motor and the power control circuit are electrically connected via the first electrical connection structure. The electrical unit according to claim 1, wherein the sensor and the control board are electrically connected via the second electrical connection structure.

8. The second electrical connection structure has a relay connector, The sensor is electrically connected to the relay connector via the first wire harness. The electrical unit according to claim 7, wherein the control board is electrically connected to the relay connector via a second wire harness.

9. The housing further comprises a power control terminal, which is housed within the housing and electrically connected to the power control circuit. The power control terminal is fastened to the first electrical connection structure by a fastener. The electrical unit according to claim 7, wherein the fastening point between the power control terminal and the first electrical connection structure is positioned so as to be exposed to the outside through the opening of the service hole.

10. The housing further includes a partition wall located between the first room and the second room. The electrical unit according to claim 7, wherein the terminal block is arranged across the first chamber and the second chamber, passing through the partition wall.

11. The motor and the sensor are housed in the first chamber of the housing. The electrical unit according to claim 10, wherein the power control circuit is housed in the second chamber of the housing.

12. The electrical unit according to claim 11, wherein the first electrical connection structure is electrically connected to the power control circuit in the second chamber.

13. The housing further comprises a power control terminal, which is housed within the housing and electrically connected to the power control circuit. The first electrical connection structure has a conductive plate that extends across the first chamber and the second chamber and is electrically connected to the motor. The power control terminal is fastened to the conductor plate of the first electrical connection structure by a fastener. The electrical unit according to claim 12, wherein the fastening location between the power control terminal and the conductor plate of the first electrical connection structure is positioned so as to be exposed to the outside through the opening of the service hole.

14. The electrical unit according to claim 11, wherein the second electrical connection structure is electrically connected to the sensor in the first chamber and electrically connected to the control board in the second chamber.

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