Electrical equipment

Abstract

This specification relates to an electrical device in which the housing is divided into a first housing and a second housing, with a plurality of terminals provided on one side and a plurality of connectors provided on the other side, and provides a structure that can mitigate the abrupt change in resistance when the second housing is coupled to the first housing. [Solution] A first terminal is provided on the first housing, and a first connector is provided on the second housing. A second terminal is provided on one of the first and second housings, and a second connector is provided on the other. When the second housing is brought closer to the first housing, the first terminal is inserted into the first connector, and the second terminal is inserted into the second connector. The first stroke, which is the length that the first terminal is inserted into the first connector, is longer than the second stroke, which is the length that the second terminal is inserted into the second connector.

Description

Technical Field

[0001] The technology disclosed in this specification relates to electrical equipment.

Background Art

[0002] Patent Documents 1 and 2 disclose an electrical device in which a motor and an inverter are housed in one housing. The housing is divided into a first housing and a second housing. The motor is housed in the first housing, and the inverter is housed in the second housing. The first housing is provided with terminals, and the second housing is provided with connectors. When the second housing is coupled to the first housing, the terminals are fitted into the connectors.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] When the first housing has a plurality of terminals, if the plurality of terminals simultaneously come into contact with their respective connectors, the resistance when the second housing is coupled to the first housing will change rapidly. This specification provides a structure that can mitigate the rapid change in resistance when the second housing is coupled to the first housing.

Means for Solving the Problems

[0005] The electrical device disclosed herein comprises a first housing having an opening; a second housing coupled to the first housing and closing the opening; a first terminal provided on the first housing and extending along the direction of the second housing approaching the first housing when the second housing is coupled to the first housing; a first connector provided on the second housing and coupled to the first terminal; a second terminal provided on one of the first and second housings and extending parallel to the first terminal; and a second connector provided on the other of the first and second housings and coupled to the second terminal. The electrical device disclosed herein further comprises a first stroke, which is the length to which the first terminal is inserted into the first connector, and a second stroke, which is the length to which the second terminal is inserted into the second connector.

[0006] As the second housing is brought closer to the first housing, the first terminal, which has a longer stroke, contacts the connector (first connector) before the second terminal. After the first terminal contacts the connector, the second terminal contacts the connector (second connector). Since the first and second terminals contact the connector sequentially, the change in resistance when coupling the second housing to the first housing is mitigated.

[0007] Details of the technology disclosed herein and further improvements are described in the following "Modes for Carrying Out the Invention". [Brief explanation of the drawing]

[0008] [Figure 1] This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment. [Figure 2] This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (the second housing is separated from the first housing). [Figure 3] This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (the knock pin is in contact with the knock hole). [Figure 4] This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (the first terminal is in contact with the first connector). [Figure 5]This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (the second terminal is in contact with the second connector). [Figure 6] This is a cross-sectional view of the electrical equipment (motor unit) of the embodiment (the second terminal block is separated from the electric motor). [Modes for carrying out the invention]

[0009] The electrical equipment of the embodiment will be described with reference to the drawings. The electrical equipment of the embodiment is a motor unit 10 in which an electric motor and an inverter are housed in a single housing.

[0010] Figure 1 shows a cross-section of the motor unit 10. In the motor unit 10, the electric motor 130, inverter 230, and controller 240 are housed in a single housing. For the sake of explanation, the "electric motor 130" will be referred to as "motor 130" below. The structure of the motor 130, inverter 230, and controller 240 is not shown in the figure.

[0011] The housing is divided into a first housing 100 and a second housing 200. The first housing 100 has an opening 101, and the second housing 200 is connected to the first housing 100 and closes the opening 101. The second housing 200 is fixed to the first housing 100 with bolts 109.

[0012] The motor 130 is housed in the first housing 100. The first housing 100 also houses a gear set (not shown). The motor unit 10 is a power unit mounted on an electric vehicle, and the main shaft of the motor 130 engages with the input gear of the gear set, while the output gear of the gear set engages with the axle. The diagram also omits the illustration of components related to the electric vehicle.

[0013] The inverter 230 and controller 240 are housed in the second housing 200. The controller 240 uses information from sensors (described later) to determine the target output of the motor 130 and controls the inverter 230 based on the target output. The inverter 230 generates AC power to drive the motor 130 based on commands from the controller 240.

[0014] The motor 130 is equipped with a sensor 140. The sensor 140 is a resolver that detects the rotation angle of the motor 130's rotor, or an oil temperature sensor that measures the oil temperature inside the motor 130. The sensor 140 is electrically connected to the controller 240 via a plurality of first terminals 111 and a first connector 210. The first connector 210 is provided with the same number of first sockets 211 as the plurality of first terminals 111. The plurality of first terminals 111 are inserted into the first connector 210, and each first terminal 111 makes contact with its respective first socket 211, electrically connecting the sensor 140 and the controller 240. Sensor signals are sent from the sensor 140 to the controller 240 via the first terminals 111 and the first connector 210. Power indicating sensor data flows through the first connector 210 and the plurality of first terminals 111.

[0015] The inverter 230 and the motor 130 are electrically connected via a plurality of second terminals 121 and a second connector 220. The second connector 220 is provided with the same number of second sockets 221 as the second terminals 121. Each second terminal 121 is inserted into the second connector 220, and each second terminal 121 makes contact with its respective second socket 221, thereby electrically connecting the motor 130 and the inverter 230. The inverter 230 generates AC power to drive the motor 130, and this AC power is supplied to the motor 130 via the plurality of second terminals 121 and the second connector 220. A large amount of power flows through the plurality of second terminals 121 and the second connector 220 to drive the motor 130.

[0016] The power flowing through the first terminal 111 and the first connector 210 is lower than the power flowing through the second terminal 121 and the second connector 220.

[0017] The plurality of first terminals 111 are provided on the first terminal block 110, and the first terminal block 110 is fixed to the inner wall of the first housing 100. In the figure, the connection point between the first terminal block 110 and the first housing 100 is not visible. The plurality of second terminals 121 are provided on the second terminal block 120, and the second terminal block 120 is fixed to the motor 130. That is, the first terminals 111 and the second terminals 121 are fixed to the first housing 100. In other words, the first terminals 111 and the second terminals 121 are provided in the first housing 100.

[0018] The first connector 210 is fixed to the controller 240, and the second connector 220 is fixed to the inverter 230. That is, the first connector 210 and the second connector 220 are fixed to the second housing 200. In other words, the first connector 210 and the second connector 220 are provided in the second housing 200.

[0019] Figure 2 shows a cross-section of the second housing 200 separated from the first housing 100. When the second housing 200 is separated from the first housing 100, the first terminal 111 moves away from the first connector 210, and the second terminal 121 moves away from the second connector 220. In the manufacturing process of the motor unit 10, the second housing 200 is brought closer to the first housing 100 along the direction of the thick arrow X in Figure 2 and coupled to the first housing 100. The first terminal 111 and the second terminal 121 extend along the direction of the second housing 200's approach to the first housing 100 when the second housing 200 is coupled to the first housing 100. Therefore, in the process of connecting the second housing 200 to the first housing 100, the first terminal 111 connects to the first connector 210 and the second terminal 121 connects to the second connector 220. However, the first stroke L1, which is the length that the first terminal 111 is inserted into the first connector 210, is longer than the second stroke L2, which is the length that the second terminal 121 is inserted into the second connector 220 (the first stroke L1 and the second stroke L2 are shown in Figure 1). This ensures that when the second housing 200 is brought closer to the first housing 100, the first terminal 111 contacts the first connector 210 before the second terminal 121 contacts the second connector 220.

[0020] The second housing 200 is provided with a knock pin 203 for relative positioning with respect to the first housing 100, and the first housing 100 is provided with a knock hole 103 into which the knock pin 203 is inserted. The knock pin 203 extends along the direction indicated by the thick arrow X in Figure 2. In other words, the knock pin 203 extends along the direction of approach of the second housing 200 when the second housing 200 is coupled to the first housing 100. The knock pin 203, the first terminal 111, and the second terminal 121 extend in parallel.

[0021] The third stroke L3, which is the length at which the knock pin 203 is inserted into the knock hole 103, is longer than the first stroke L1, which is the length at which the first terminal 111 is inserted into the first connector 210 (the third stroke L3 is also shown in FIG. 1). This means that when the second housing 200 approaches the first housing 100, the knock pin 203 contacts the knock hole 103 before the first terminal 111 contacts the first connector 210. That is, when coupling the second housing 200 to the first housing 100, first the knock pin 203 contacts the knock hole 103, then the first terminal 111 contacts the first connector 210, and finally the second terminal 121 contacts the second connector 220. The relationship L3 > L1 > L2 ensures this contact order.

[0022] FIG. 3 shows a state where the separated second housing 200 approaches the first housing 100 and the knock pin 203 contacts the knock hole 103. Arrow A indicates the contact point between the knock pin 203 and the knock hole 103. At this time, a distance B is secured between the first terminal 111 and the first connector 210, and a distance C is secured between the second terminal 121 and the second connector 220.

[0023] When the second housing 200 further approaches the first housing 100, the tip of the knock pin 203 is inserted into the knock hole 103, and the position of the second housing 200 relative to the first housing 100 is accurately determined. Subsequently, the first terminal 111 contacts the first connector 210.

[0024] FIG. 4 shows a state where the tip of the first terminal 111 contacts the first connector 210. Arrow D indicates the contact point between the first terminal 111 and the first connector 210. At this time, a distance E is secured between the second terminal 121 and the second connector 220.

[0025] When the second housing 200 further approaches the first housing 100, the tip of the first terminal 111 is inserted into the first connector 210, and at the same time the tip of the second terminal 121 contacts the second connector 220.

[0026] Figure 5 shows the state in which the tip of the second terminal 121 is in contact with the second connector 220. Arrow F indicates the contact point between the second terminal 121 and the second connector 220. At this time, the tip of the first terminal 111 is already inserted into the first connector 210.

[0027] As the second housing 200 moves further towards the first housing 100, the flange of the second housing 200 comes into contact with the flange of the first housing 100. Figure 1 shows the final state in which the second housing 200 is coupled to the first housing 100.

[0028] As mentioned earlier, when the second housing 200 is brought closer to the first housing 100, the knock pin 203 first contacts the knock hole 103, then the first terminal 111 contacts the first connector 210, and finally the second terminal 121 contacts the second connector 220. The relationship L3 > L1 > L2 guarantees this contact order. The advantages of the sequential contact of the knock pin 203, the first terminal 111, and the second terminal 121 will be explained.

[0029] Prior to the first terminal 111 and the second terminal 121 making contact with the connector, the tip of the knock pin 203 is inserted into the knock hole 103. Prior to the first terminal 111 and the second terminal 121 making contact with the connector, the second housing 200 is precisely positioned relative to the first housing 100. Thus, the first terminal 111 is securely inserted into the first connector 210 and the second terminal 121 is securely inserted into the second connector 220.

[0030] As the first terminal 111 and the second terminal 121 sequentially contact the connector, the resistance force when bringing the second housing 200 closer to the first housing 100 gradually increases. If the first stroke and the second stroke were the same, the first terminal 111 and the second terminal 121 would contact their respective connectors simultaneously. As a result, the resistance force when bringing the second housing 200 closer to the first housing 100 would change abruptly. The abrupt increase in resistance force is mitigated by the first stroke L1 being different from the second stroke L2.

[0031] Furthermore, the power flowing through the first terminal 111 is lower than the power flowing through the second terminal 121, and the first terminal 111 can be thinner and weaker than the second terminal 121. The resistance when inserting the first terminal 111 into the first connector 210 is lower than the resistance when inserting the second terminal 121 into the second connector 220. This characteristic also has advantages. The first terminal 111 begins to be inserted into the first connector 210 before the second terminal 121 is inserted into the second connector 220. Subsequently, if the resistance when bringing the second housing 200 closer to the first housing 100 changes even slightly, an insertion error of the first terminal 111 can be inferred. If the second terminal 121, which has a higher resistance, makes contact with the connector before the first terminal 111, the resistance of the second terminal 121 is so high that even a slight change in resistance between the first terminal 111 and the first connector 210 may not be detected. By making contact with the connector first using terminals with low resistance, the sensitivity for detecting insertion errors can be increased.

[0032] Figure 6 shows the second terminal block 120 separated from the motor 130. The second terminal block 120 is provided with knock pins 123, and the motor 130 is provided with knock holes 124. The knock pins 123 and knock holes 124 determine the precise position of the second terminal block 120 relative to the motor 130. Knock pins 123 and 203 extend in parallel. It is preferable that knock pins 203 and 123 are the same size, and that knock holes 103 and 124 are also the same size. This improves the machining efficiency of the knock pins and knock holes. Although not shown in the figure, it is preferable that the knock pins (knock holes) for positioning the first terminal block 110 on the first housing 100 be the same size as knock pins 203 (knock holes 103).

[0033] The following points concern the technology described in the embodiment. The thick arrow line X in Figure 2 indicates the direction in which the second housing 200 approaches the first housing 100 when the second housing 200 is joined to the first housing 100. The knock pin 203 that determines the relative positions of the first housing 100 and the second housing 200 extends along the thick arrow line X. In other words, the direction in which the second housing 200 approaches the first housing 100 when the second housing 200 is joined to the first housing 100 can also be expressed as the direction in which the knock pin 203 that determines the relative positions of the first housing 100 and the second housing 200 extends.

[0034] The first stroke L1 refers to the length of the first terminal 111 that is inserted into the first connector 210. The same applies to the second stroke L2. The third stroke L3 refers to the length of the knock pin 203 that is inserted into the knock hole 103.

[0035] In the motor unit 10, a positioning knock pin 203 is provided in one of the first housing 100 and the second housing 200, and a knock hole 103 into which the knock pin 203 engages is provided in the other. It is preferable that the stroke of the knock pin 203 (third stroke L3) is longer than the first stroke L1.

[0036] "The resistance force when inserting the first terminal 111 into the first connector 210" refers to the force generated between the first terminal 111 and the first connector 210 when inserting the first terminal 111 into the first connector 210, and means a force that occurs in the direction opposite to the insertion direction. In other words, "the resistance force when inserting the first terminal 111 into the first connector 210" refers to the frictional force generated between the first terminal 111 and the first connector 210 when inserting the first terminal 111 into the first connector 210. "The resistance force when inserting the second terminal 121 into the second connector 220" has the same meaning.

[0037] The terms "first housing 100" and "second housing 200" are merely convenient designations to distinguish between the two separated housings. The terms "first housing 100" (and "second housing 200") can also be replaced with "second housing" (and "first housing"). The same applies to the terms "first terminal 111" and "second terminal 121," and "first connector 210" and "second connector 220."

[0038] In the motor unit 10, the first terminal 111 and the first connector 210, and the second terminal 121 and the second connector 220 only need to be connected through the opening 101 of the housing. The knock pins 203 that position the first housing 100 and the second housing 200 extend perpendicularly to the surface of the opening 101 (opening surface).

[0039] In the motor unit 10 of this embodiment, the first terminal 111 and the second terminal 121 are fixed to the first housing 100, and the first connector 210 and the second connector 220 are fixed to the second housing 200. Alternatively, the first terminal 111 and the second connector 220 may be fixed to the first housing 100, and the second terminal 121 and the first connector 210 may be fixed to the second housing 200. That is, the second terminal 121 may be fixed to one of the first housing 100 and the second housing 200, and the second connector 220 may be fixed to the other of the first housing 100 and the second housing 200. In other words, the second terminal 121 may be provided on one of the first housing 100 and the second housing 200, and the second connector 220 may be provided on the other of the first housing 100 and the second housing 200.

[0040] The electrical equipment of this embodiment is a motor unit 10 comprising a motor 130, an inverter 230, and a controller 240. The housing of the motor unit 10 is divided into a first housing 100 and a second housing 200. The first housing 100 houses the electric motor 130, and the second housing 200 houses the inverter 230 that drives the electric motor 130 and the controller 240 that controls the inverter 230. Alternatively, the electric motor 130 may be housed in the second housing 200, and the inverter 230 and controller 240 may be housed in the first housing 100. That is, the electric motor 130 may be housed in one of the first housing 100 and the second housing 200, and the inverter 230 and controller 240 may be housed in the other. The first terminal 111 and the first connector 210 connect the sensor 140 associated with the electric motor 130 and the controller 240. The second terminal 121 and the second connector 220 connect the electric motor 130 and the inverter 230.

[0041] The technology disclosed herein is not limited to the motor unit 10. The technology disclosed herein can be applied to any structure comprising an electrical device and a housing that houses and divides the electrical device. The first housing may be referred to as the “housing body having an opening,” and the second housing may be referred to as the “housing cover closing the opening.” The first terminal and the first connector, and the second terminal and the second connector electrically connect the electrical device in the first housing and the electrical device in the second housing.

[0042] Although specific examples of the present invention have been described in detail above, these are merely illustrative and do not limit the scope of the claims. The technologies described in the claims include various modifications and changes to the specific examples illustrated above. The technical elements described in this specification or 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. Furthermore, the technologies illustrated in this specification or drawings can achieve multiple objectives simultaneously, and achieving even one of these objectives itself constitutes technical usefulness. [Explanation of Symbols]

[0043] 10: Motor unit (electrical equipment) 100: First housing 101: Opening 103, 124: Knock holes 109: Bolt 110: First terminal block 111: First terminal 120: Second terminal block 121: Second terminal 123, 203: Knock pins 130: Electric motor 140: Sensor 200: Second housing 210: First connector 211: First socket 220: Second connector 221: Second socket 230: Inverter 240: Controller

Claims

1. A first housing having an opening, A second housing that connects to the first housing to close the opening, A first terminal provided on the first housing and extending along the direction in which the second housing approaches the first housing when the second housing is coupled to the first housing, A first connector is provided in the second housing and is connected to the first terminal, A second terminal is provided on one of the first housing and the second housing, and extends parallel to the first terminal, A second connector is provided on the other side of the first housing and the second housing and is coupled to the second terminal, It is equipped with, An electrical device in which the first stroke, which is the length the first terminal is inserted into the first connector, is longer than the second stroke, which is the length the second terminal is inserted into the second connector.

2. The electrical device according to claim 1, wherein the resistance when inserting the first terminal into the first connector is lower than the resistance when inserting the second terminal into the second connector.

3. An electric motor is housed in one of the first and second housings, and an inverter for driving the electric motor and a controller for controlling the inverter are housed in the other of the first and second housings. The first terminal and the first connector connect the sensor related to the electric motor and the controller. The electrical equipment according to claim 1 or 2, wherein the second terminal and the second connector connect the electric motor and the inverter.

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