Connection structure

Abstract

The objective is to provide a connection structure that is simple and can be miniaturized. [Solution] A connection structure comprising a first unit and a second unit, wherein the first unit has a first case, an inverter, a first terminal, and a terminal block, the inverter is housed in the first case, the first terminal is connected to the inverter and fixed to the terminal block, and the second unit has a second case, a motor, and a second terminal, the motor and the second terminal are housed in the second case, the second terminal is connected to the motor, the terminal block is located at the end of the first case on the side of the second case, protrudes from the first case into the interior of the second case, the first terminal protrudes from the first case into the interior of the second case and is connected to the second terminal.

Description

Technical Field

[0001] The present invention relates to a connection structure.

Background Art

[0002] In order to electrically connect a motor and an inverter, the terminals on the motor side and the terminals on the inverter side are connected by bolt fastening or the like (for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] A motor, terminals, and a terminal block are made into one unit. An inverter, terminals, and a terminal block are made into another unit. These units may be combined. However, the structure is complex and large. Therefore, an object is to provide a connection structure capable of simplifying and miniaturizing the structure.

Means for Solving the Problems

[0005] The above object can be achieved by a connection structure including a first unit and a second unit, the first unit having a first case, an inverter, a first terminal, and a terminal block, the inverter being housed in the first case, the first terminal being connected to the inverter and fixed to the terminal block, the second unit having a second case, a motor, and a second terminal, the motor and the second terminal being housed in the second case, the second terminal being connected to the motor, the terminal block being located at an end of the first case on the side of the second case and protruding from the first case into the interior of the second case, the first terminal protruding from the first case into the interior of the second case and being connected to the second terminal.

[0006] The first unit may have a plurality of first terminals, the plurality of first terminals being fixed to the terminal block, and the second unit may have a plurality of second terminals, the plurality of first terminals being connected to the plurality of second terminals.

[0007] The terminal block and the second case may be sealed.

[0008] The first terminal and the second terminal may be connected by bolt fastening.

[0009] One of the first terminal and the second terminal may be plugged into the other. [Effects of the Invention]

[0010] This provides a connection structure that is simple and can be miniaturized. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1(a) is a front view illustrating a connection structure according to an embodiment. Figure 1(b) is a side view illustrating a connection structure. [Figure 2] Figures 2(a) to 2(e) are enlarged cross-sectional views of the area around the terminal block. [Figure 3] Figures 3(a) and 3(b) illustrate a method for manufacturing a connecting structure. [Figure 4] Figures 4(a) and 4(b) show another example of the manufacturing method. [Figure 5] Figure 5 shows another example of a manufacturing method. [Modes for carrying out the invention]

[0012] <First Embodiment> The connection structure of this embodiment will now be described with reference to the drawings. Figure 1(a) is a front view illustrating the connection structure 100 according to the embodiment. Figure 1(b) is a side view illustrating the connection structure 100. These figures show the connection structure 100 in perspective. The connection structure 100 is an eAxle and includes a power control unit 10 (PCU: Power Control Unit, first unit) and an MG (Motor Generator) unit 20 (second unit). The connection structure 100 is mounted on a vehicle or the like.

[0013] The PCU10 and MG unit 20 are aligned in the Z-axis direction and connected to each other. Figure 1(a) shows the YZ plane. Figure 1(b) shows the XZ plane. The X-axis, Y-axis, and Z-axis directions are orthogonal to each other.

[0014] The PCU 10 comprises a power card 12, busbars 14 (first terminals), a terminal block 16, and a case 17 (first case), and may also include an ECU (Electronic Control Unit) and a current sensor, etc. (not shown). The power card 12 and busbars 14 are housed inside the case 17. The power card 12 includes an inverter, etc. The inverter includes switching elements such as IGBTs (Insulated Gate Bipolar Transistors). Multiple busbars 14 are electrically connected to the power card 12 and fixed to the terminal block 16.

[0015] The MG unit 20 includes a motor 22, terminals 24 (second terminals), a case 26 (second case), and a cover 28. Multiple terminals 24 are electrically connected to the motor 22. The motor 22 and terminals 24 are housed inside the case 26. The cover 28 is attached to the X-side end of the case 26.

[0016] The terminal block 16 is provided at the end of the case 17 on the MGPCU 10 side and protrudes from the case 17 to the inside of the case 26. The bus bar 14 penetrates the terminal block 16 in the Z-axis direction and protrudes from the case 17 to the inside of the case 26. The terminal 24 is electrically connected to the bus bar 14. By fastening the bolt 30, the terminal 24 and the bus bar 14 are fixed to each other.

[0017] The inverter included in the power card 12 converts DC power into AC power and also converts AC power into DC power. The motor 22 functions as a driving power source and a generator. The motor 22 rotates by the input of power and outputs a driving force. The motor 22 rotates, for example, by a driving force input from an engine (not shown) and generates power.

[0018] Figures 2(a) to 2(e) are enlarged cross-sectional views of the vicinity of the terminal block and show variations of the seal structure. Any of Figures 2(a) to 2(e) may be adopted. In any of these, the terminal block 16 and the bus bar 14 protrude from the inside of the case 17 to the inside of the case 26. The bus bar 14 penetrates the terminal block 16.

[0019] In the example of Figure 2(a), the bolt 31 penetrates the case 26 and is inserted into the terminal block 16. The terminal block 16 is fixed to the case 26 by a plurality of bolts 31. The sealing material 32 is provided in the gap between the terminal block 16 and the case 26. The sealing material 32 is, for example, made of rubber and seals the gap between the terminal block 16 and the case 26.

[0020] In the example of Figure 2(b), a screw 33 and a nut 34 are provided. The screw 33 is a straight type, penetrates the case 26, and is inserted into the terminal block 16. The nut 34 is attached to the screw 33.

[0021] In the example of Fig. 2(c), the spring 35 is provided between the case 17 and the terminal block 16, pressing the terminal block 16 against the case 26. The sealing material 32 is provided between the terminal block 16 and the case 26, for example, directly below the spring 35. The elastic force of the spring 35 causes the sealing material 32 to deform, sealing the space inside the case 17.

[0022] The example of Fig. 2(d) has a sealing material 32, a spring 36, and a plate 37. The sealing material 32 is provided at the same position as in Fig. 2(c). The plate 37 is located on the side of the case 26 opposite to the terminal block 16 and is attached to the terminal block 16. The spring 36 is provided between the plate 37 and the case 26. The spring 36 presses the terminal block 16 against the case 26.

[0023] In the example of Fig. 2(e), the fastening seat 38 is provided inside the case 17. The terminal block 16 is fixed to the case 17 by bolts 31. The sealing material 32 seals the space between the terminal block 16 and the case 26.

[0024] Figs. 3(a) and 3(b) are diagrams illustrating the manufacturing method of the connection structure 100. As shown in Fig. 3(a), the cover 28 is not attached to the case 26 of the MG unit 20, and one surface is open. The motor 22 is assembled into the case 26 from the open portion. The power card 12, the bus bar 14, and the terminal block 16 are attached to the case 17 of the PCU 10.

[0025] As shown in Fig. 3(b), the bus bar 14 and the terminal block 16 of the PCU 10 are inserted into the case 26. The bus bar 14 and the terminal 24 are connected. An operator reaches in through the empty portion of the case 26 and fastens the bolt 30 with a tool or the like. When attaching the terminal block 16 to the case 26, the sealing structure shown in Figs. 2(a) to 2(e) is also formed. After the connection of the terminals and the formation of the sealing structure, the cover 28 is attached to the case 26, resulting in the state of Fig. 1(b).

[0026] Figures 4(a) and 4(b) show another example of the manufacturing method. As shown in Figure 4(a), the motor 22 and cover 28 are not mounted in the case 26 of the MG unit 20. The power card 12, busbar 14, and terminal block 16 are mounted in the case 17 of the PCU 10. The terminal block 16 of the PCU 10 is inserted into the case 26. As shown in Figure 4(b), after connecting the PCU 10 and the MG unit 20, the motor 22 is mounted in the case 26 and the busbar 14 and terminal 24 are secured. Then the cover 28 is attached to the case 26.

[0027] Figure 5 shows another example of the manufacturing method. In the example in Figure 5, the busbar 14 is one of the male and female types. The terminal 24 is the other of the male and female types. Before the MG unit 20 and PCU 10 are connected, the motor 22 and cover 28 are attached to the case 26 of the MG unit 20. One of the busbars 14 and terminal 24 can be inserted into the other without using fasteners such as bolts.

[0028] According to this embodiment, the PCU 10 has a busbar 14 and a terminal block 16. The busbar 14 is fixed to the terminal block 16. The terminal block 16 is provided at the end of the case 17 that faces the case 26. By attaching the terminal block 16 to the case 26 of the MG unit 20, the busbar 14 is also positioned inside the case 26. The terminal block 16 and the busbar 14 protrude from the case 17 into the interior of the case 26. The PCU 10 and the MG unit 20 can be connected by connecting the busbar 14 to the terminal 24. The MG unit 20 does not have a terminal block. This reduces the number of parts, simplifies the structure, and allows for miniaturization.

[0029] Since multiple busbars 14 are fixed to the terminal block 16, connecting to multiple terminals 24 is easy. Furthermore, the structure can be simplified.

[0030] As shown in Figures 2(a) to 2(e), the space between the terminal block 16 and the case 26 is sealed with a sealing material 32. This protects the power card 12 and the motor 22.

[0031] The busbar 14 and terminal 24 are connected by tightening the bolt 30. Assembly can be carried out in the appropriate order, as shown in the examples in Figures 3(a) and 3(b), and in Figures 4(a) and 4(b). Specifically, the busbar 14 and terminal 24 are connected before attaching the cover 28 to the case 26. Since one side of the case 26 is open, work inside the case 26 is easy. The bolt 30 can be tightened using tools. A service hole does not need to be provided in the case 26.

[0032] As shown in the example in Figure 5, the busbar 14 may be inserted into the terminal 24. Assembly is possible without using bolts or other fasteners. After attaching the cover 28 to the case 26, the busbar 14 and terminal 24 can be connected.

[0033] Although preferred embodiments of the present invention have been described in detail above, the present invention is not limited to these specific embodiments, and various modifications and changes are possible within the scope of the gist of the invention as described in the claims. [Explanation of symbols]

[0034] 10 PCU (1st unit), 12 Power card, 14 Busbar (1st terminal), 16 Terminal block, 17, 26 Case, 20 Motor unit (2nd unit), 22 Motor, 24 Terminal (2nd terminal), 28 Cover, 30, 31 Bolt, 32 Seal material, 33 Screw, 34 Nut, 35, 36 Spring, 37 Plate, 38 Fastening seat, 100 Connection structure

Claims

1. The first unit and, The second unit is equipped with, The first unit comprises a first case, an inverter, a first terminal, and a terminal block. The inverter is housed in the first case, The first terminal is connected to the inverter and fixed to the terminal block. The second unit comprises a second case, a motor, and a second terminal. The motor and the second terminal are housed in the second case. The second terminal is connected to the motor, The terminal block is located at the end of the first case that faces the second case, and protrudes from the first case into the interior of the second case. A connection structure in which the first terminal protrudes from the first case into the interior of the second case and is connected to the second terminal.

2. The first unit has a plurality of first terminals, The plurality of first terminals are fixed to the terminal block. The second unit has a plurality of the second terminals, The connection structure according to claim 1, wherein the plurality of first terminals are connected to the plurality of second terminals.

3. The connection structure according to claim 2, wherein the terminal block and the second case are sealed together.

4. The connection structure according to claim 1 or claim 2, wherein the first terminal and the second terminal are connected by bolt fastening.

5. The connection structure according to claim 1 or claim 2, wherein one of the first terminal and the second terminal is inserted into the other.

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