Motor device and method of manufacturing the same

Abstract

In the present invention, a cover-side terminal of a motor cover, in an extending direction of a motor terminal of a motor case, is press-fit and fixed electrically to the motor terminal at a first position separated from a base part by a first length. In contrast, a fixed part of the motor cover, in the extending direction of the motor terminal of the motor case, is press-fit and fixed to a projecting part at a second position separated from the base part by a second length different from the first length. In this case, for example, the second length is longer than the first length.

Description

[Technical Field]

[0001] The present disclosure relates to a motor device and Motor device manufacturing method By law Regarding. [Background technology]

[0002] Patent Document 1 discloses a motor that can individually manage the press-fit state of multiple terminals based on the press-fit load. With this motor, the bus bars all protrude from the motor surface at different heights. Therefore, the timing at which each terminal is press-fitted into the slits of the bus bars also differs. Each time a terminal starts to be press-fitted into a slit, the slope of the load detected by the load sensor changes. That is, the detected load individually reflects the press-fit state of each of the three terminals as a change in slope. Therefore, it is possible to manage the press-fit state of each terminal based on the load. Furthermore, Patent Documents 2 to 4, for example, describe electric brake devices that apply braking force based on the drive of a motor. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-004616 [Patent Document 2] Japanese Patent Application Laid-Open No. 2016-161025 [Patent Document 3] Japanese Patent Application Publication No. 2019-130939 [Patent Document 4] Japanese Patent Publication No. 2020-008134 Summary of the Invention [Problem to be solved by the invention]

[0004] However, if the timing of press-fitting the motor terminal and the electrical connection terminal and the timing of press-fitting the press-fit portion for mechanically fixing the motor to the housing are set to approximately the same, the timing of load generation will be approximately the same. This may make it difficult to confirm whether the motor terminal and the electrical connection terminal are properly mated. In response to this, Patent Document 1 discloses that the press-fitting state of each terminal portion is managed based on the load by varying the press-fitting timing of multiple terminals. However, this does not take into account the influence of the press-fitting timing of two portions with different functions, as described above.

[0005] An object of one embodiment of the present invention is to provide a motor device that can suppress deterioration of the mating state between a terminal (e.g., a motor terminal) and an electrical connection portion (electrical connection terminal) when two portions with different functions are press-fitted together. and Motor device manufacturing method The law The purpose is to provide. [Means for solving the problem]

[0006] One embodiment of the present invention is a motor comprising a motor case and a motor cover, wherein the motor case comprises a motor, terminals connected to the motor, and a case body that houses the motor, the case body having a base from which the terminals extend and a protruding portion that protrudes from the base at a position separate from the terminals, and the motor cover has a first position on the inside that is spaced a first length from the base in the direction in which the terminals extend and is electrically press-fitted and fixed to the terminals. It is a structure an electrical connection portion, which is press-fitted and fixed to the protrusion at a second position spaced a second length different from the first length from the base portion in the extending direction of the terminal, with a press-fit load higher than the press-fit load of the electrical connection portion; It is a structure and a fixed portion that serves as a mechanical connection site, wherein the second length is longer than the first length.

[0007] Furthermore, one embodiment of the present invention provides a motor case including a first step of preparing a motor case including a motor, terminals connected to the motor, and a case body that houses the motor, the case body having a base from which the terminals extend and a protruding portion that protrudes from a position on the base different from that of the terminals; an electrical connection portion that is electrically fixed to the terminals; and a fixing portion that is press-fitted and fixed to the protruding portion to serve as a mechanical connection portion. Inside a first press-fitting timing at which the terminal is press-fitted into the electrical connection portion from the extending direction of the terminal; and a second press-fitting timing at which the protruding portion is press-fitted into the fixing portion from the extending direction of the terminal. A press-fit load higher than the press-fit load of the electrical connection part a second press-fitting timing at which the press-fitting is performed; is different and a third step of fixing the motor case and the motor cover to each other so that the motor case and the motor cover are fixed to each other. In the third step, the first press-fitting timing is earlier than the second press-fitting timing. A method for manufacturing a motor device.

[0010] According to one embodiment of the present invention, when two parts with different functions are press-fitted together, it is possible to prevent deterioration of the fitted state between a terminal (for example, a motor terminal) and an electrical connection portion (electrical connection terminal). [Brief explanation of the drawings]

[0011] [Figure 1] 1 is an outline view showing an electric brake device including a motor device (terminal connection mechanism) according to an embodiment. [Figure 2] 2 is an outline view showing the motor device (terminal connection mechanism) removed from the electric brake device in FIG. 1, and the motor case (first housing) and the motor cover (second housing) separated from each other. FIG. [Figure 3] 1A to 1D are partial cross-sectional outline drawings showing the states when the motor case (first housing) and the motor cover (second housing) are fixed together in stages. [Figure 4] 5 is a characteristic diagram showing an example of the relationship between the stroke and the load when fixing the motor case (first housing) and the motor cover (second housing). [Figure 5]FIG. 10 is a characteristic diagram showing an example of the relationship between the stroke and the load when fixing the motor case (first housing) and the motor cover (second housing) according to a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, a motor device (terminal connection mechanism) according to an embodiment will be described with reference to the accompanying drawings, taking as an example a case where it is mounted on an electric brake device of a four-wheeled automobile.

[0013] 1 to 4 show an embodiment. In FIG. 1, an electric brake device 1 corresponds to, for example, a hydraulic disc brake equipped with an electric motor (a hydraulic disc brake with an electric parking brake function). The electric brake device 1 is mounted on a vehicle (automobile) (not shown). The electric brake device 1 includes a brake main body 2 and an electric actuator 3.

[0014] The brake main body 2 includes, for example, a mounting member called a carrier, a caliper as a wheel cylinder, a pair of brake pads as braking members (friction members, friction pads), and a piston as a pressing member. In this case, the caliper and piston form a cylinder mechanism, that is, a cylinder mechanism in which the piston moves due to hydraulic pressure and presses the brake pads against the disc rotor. The brake main body 2 corresponds to a hydraulic brake mechanism (hydraulic brake) that applies braking force by pressing the brake pads against the disc rotor using hydraulic pressure. The disc rotor as the braked member (rotating member) rotates together with the vehicle wheel.

[0015] The electric actuator unit 3 includes a motor unit 4, a motor unit cover 5, a reducer 6, a reducer cover 7, and a rotary-to-linear motion conversion mechanism. The motor unit 4 includes a motor 12 (coil and permanent magnet) that serves as a propulsion source (drive source) for propelling the piston of the brake main body unit 2. The motor unit cover 5 is a cover member for the motor unit 4 that shields and holds the motor case 11 (motor 12) of the motor unit 4 from the outside air. The motor unit cover 5 is provided with a flange portion 5A. A flange portion 27 of the motor cover 21 of the motor unit 4 is screwed to the flange portion 5A of the motor unit cover 5 using screws (not shown). This holds the motor unit 4 in place in the motor unit cover 5.

[0016] The reducer 6 is, for example, a gear-type reducer. The reducer 6 reduces the rotation of the motor 12 and transmits it to the rotary-to-linear conversion mechanism. The reducer cover 7 is a cover member for the reducer 6 that protects the reducer 6 from the outside air. That is, the multiple gears that make up the reducer 6 are rotatably supported within the reducer cover 7. The motor device cover 5 and the reducer cover 7 may be formed as separate bodies, or may be formed integrally as a single cover. As shown in FIG. 1 , the motor device 4, the reducer 6, the motor device cover 5, and the reducer cover 7 constitute a motor gear unit 8, which is an assembly of these components.

[0017] The rotary-to-linear motion conversion mechanism is also called a rotary-to-linear motion mechanism, and is provided, for example, inside the piston of the brake main body 2. The rotary-to-linear motion conversion mechanism constitutes a holding mechanism (pressing member holding mechanism) that holds the pressing force of the brake pad. The rotary-to-linear motion conversion mechanism is composed, for example, of a screw member made of a rod-shaped body with an external thread formed therein, and a linear motion member that serves as a propulsion member with an internally threaded hole formed on its inner periphery. The rotary-to-linear motion conversion mechanism converts the rotation of the motor 12 into axial displacement of the piston, and holds the piston propelled by the motor 12.

[0018] In this embodiment, the electric brake device 1 propels a piston by brake fluid pressure generated based on brake pedal operation or the like, causing the brake pads to press against a disc rotor, thereby applying a braking force to the wheels and ultimately to the vehicle. In addition, the electric brake device 1 propels the piston via a rotary-to-linear motion conversion mechanism using a motor 12 in response to an operation request based on a signal from a parking brake switch or the like, thereby applying a braking force (parking brake, auxiliary brake while traveling) to the vehicle. For this purpose, the electric brake device 1 is equipped with a motor device 4. Note that the basic configurations of the brake main body 2 and electric actuator 3 of the electric brake device 1 are publicly known from various documents, including the aforementioned Patent Documents 2-4, and therefore further explanation of the basic configuration will be omitted.

[0019] In addition, in the embodiment, a hydraulic disc brake equipped with an electric motor has been described as an example of the electric brake device 1. However, the electric brake device is not limited to this, and other electric brake devices may be used, for example, an electric disc brake equipped with an electric caliper, an electric drum brake in which an electric motor presses a shoe against a drum to apply braking force, a disc brake equipped with an electric drum-type parking brake, or a cable-puller-type electric parking brake in which an electric motor pulls a cable to apply and operate the parking brake. In other words, the electric brake device 1 can use various electric brakes (electric brake mechanisms) as long as it is configured to press (propel) friction members (pads, shoes) against rotating members (rotor, drum) based on the drive of an electric motor and to maintain and release the pressing force.

[0020] Next, the motor device 4 as the terminal connection mechanism will be described with reference to FIGS. 2 to 4 in addition to FIG.

[0021] As shown in Fig. 2, the motor device 4 includes a motor case 11 as a first housing and a motor cover 21 as a second housing. Fig. 2 shows the motor case 11 and the motor cover 21 that constitute the motor device 4 in a separated state. That is, Fig. 2 shows the state before the motor case 11 and the motor cover 21 are fixed to each other (before assembly). In contrast, Fig. 1 shows the state after the motor case 11 and the motor cover 21 are fixed to each other, assembled into the electric brake device 1 (more specifically, the motor gear unit 8).

[0022] 1 shows the motor device 4, in which the motor case 11 and the motor cover 21 are fixed to each other, attached to the motor device cover 5 of the electric brake device 1 (more specifically, the motor gear unit 8). This attachment can be performed, for example, by abutting the flange portion 27 of the motor cover 21 of the motor device 4 and the flange portion 5A of the motor device cover 5 and fastening them together using screws (not shown).

[0023] 2, the motor case 11 of the motor device 4 includes a motor 12, motor terminals 13 as terminals, and a case body 14. The motor 12 includes, for example, a stator formed of a coil, and a rotor formed of a permanent magnet rotatably provided in the center of the stator. Note that the coil may serve as the rotor, and the permanent magnet may serve as the stator.

[0024] The motor terminal 13 is connected to the motor 12. For example, the motor terminal 13 is connected to the coil of the motor 12. The motor terminal 13 is connected to the cover-side terminal 24 of the motor cover 21 by press-fitting. The motor terminal 13 is configured as, for example, a flat plate-shaped terminal. Power is supplied to the motor 12 (coil) via the cover-side terminal 24 and the motor terminal 13. The case body 14 houses the motor 12. Conversely, the motor 12 is housed in the case body 14.

[0025] The case body 14 has a base 15 and a protruding portion 16. The base 15 closes one end of the case body 14, i.e., the side facing the motor cover 21. The motor terminal 13 extends from the base 15. That is, the motor terminal 13 extends from the base 15 toward the motor cover 21. The protruding portion 16 protrudes from the base 15. That is, the protruding portion 16 protrudes from the base 15 toward the motor cover 21. The protruding portion 16 is formed on the base 15 as, for example, a cylindrical member. The base 15 is press-fitted and fixed into a fixing portion 25 of the motor cover 21.

[0026] On the other hand, the motor cover 21, which serves as a motor cap, has the function of holding the motor 12. The motor cover 21 is, for example, molded from resin and is formed into a generally cylindrical shape with a bottom. The motor cover 21 is provided with a motor device-side connector 22 into which a vehicle-side connector (vehicle-side connector) is fitted. The motor cover 21 also has a flange portion 27 that abuts against the flange portion 5A of the motor device cover 5 when the motor device 4 is attached to the motor device cover 5. The flange portion 27 of the motor cover 21 and the flange portion 5A of the motor device cover 5 are fastened together using, for example, screws (not shown).

[0027] A conductive member 23 having conductivity for supplying power to the motor 12 is insert-molded into the motor cover 21. One end of the conductive member 23 has a flat plate shape that connects to a connector on the vehicle side. The other end of the conductive member 23 has a cover-side terminal 24 that connects to the motor terminal 13 on the motor 12 side. The cover-side terminal 24 is also called a bus bar, for example, and is configured as a crocodile-claw-shaped connection terminal (alligator-claw-shaped terminal). That is, the cover-side terminal 24 is configured as, for example, a flat plate-shaped terminal and has a notch portion into which the plate-shaped motor terminal 13 is press-fitted by sandwiching it inside. As a result, the cover-side terminal 24 is formed into a generally U-shaped or Y-shaped overall shape.

[0028] The cover-side terminals 24 are electrically connected to the motor terminals 13 and are press-fitted into the motor terminals 13. That is, the cover-side terminals 24 and the motor terminals 13 are electrically connected by press-fitting between the terminals. Furthermore, the motor case 11 including the motor 12 and the motor cover 21 are mechanically connected at a location separate from the connection location (electrical connection location) between the cover-side terminals 24 and the motor terminals 13. That is, the motor case 11 and the motor cover 21 are held together by press-fitting (press-fitting) the protrusions 16 on the motor case 11 and the fixing portions 25 on the motor cover 21.

[0029] As described above, the motor cover 21 includes cover-side terminals 24 as electrical connection portions that are electrically press-fitted and fixed to the motor terminals 13 of the motor case 11, and fixing portions 25 that are press-fitted and fixed to the protrusions 16 of the motor case 11. The electrical connection is achieved by press-fitting the motor terminals 13 into the alligator-like fitting portions of the cover-side terminals 24. The fitting portions of the cover-side terminals 24 correspond to locations that are narrower than the plate thickness of the motor terminals 13.

[0030] Meanwhile, the mechanical connection is achieved by press-fitting a cylindrical protrusion 16 provided on the motor case 11 side with a cylindrical fixing portion 25 provided on the motor cover 21 side. In this case, as shown in Fig. 3, a plurality of ribs 26 are provided circumferentially spaced apart in the fixing portion 25 of the motor cover 21 so that the inner diameter of the fixing portion 25 is smaller than the outer diameter of the protrusion 16. Therefore, the protrusion 16 is press-fit into the portion inside the fixing portion 25 where the inner diameter is narrower than the outer diameter of the protrusion 16, i.e., the portion corresponding to the ribs 26.

[0031] That is, when the motor case 11 and the motor cover 21 are fixed to each other, the columnar protrusion 16 and the cylindrical fixing portion 25 are press-fitted starting from a portion (a portion corresponding to the rib 26) where the inner diameter of the fixing portion 25 is smaller than the outer diameter of the protrusion 16. Thereafter, the protrusion 16 is inserted into the fixing portion 25 until the end face of the base 15, which becomes the abutment surface 17 of the motor case 11, abuts against the tip of the fixing portion 25 of the motor cover 21. As a result, the positions of the motor case 11 and the motor cover 21 are fixed to each other.

[0032] In this state, the press-fit portions between the protrusions 16 and the fixing portions 25 and the press-fit portions between the motor terminals 13 and the cover-side terminals 24 are entirely covered by the motor cover 21 and the case body 14 (more specifically, the base 15) of the motor case 11. That is, the respective press-fit portions are covered while the motor case 11 and the motor cover 21 are being fixed to each other and when the motor case 11 and the motor cover 21 are fixed to each other. In other words, when fixed to the motor case 11, the motor cover 21 has a shape (a cylindrical shape with a bottom) that covers the protrusions 16, the fixing portions 25, the motor terminals 13, and the cover-side terminals 24 from the outside. That is, the motor cover 21 has a cylindrical main body portion 29 (a lid portion) with a bottom and that has the fixing portions 25 and the motor terminals 13 on the inside.

[0033] In this embodiment, there are provided two press-fit portions formed by motor terminals 13 and cover-side terminals 24 for electrically connecting motor 12, and one press-fit portion formed by resin protrusion 16 and fixing portion 25 for mechanically fixing motor 12. That is, in this embodiment, motor cover 21 and motor case 11 have multiple press-fit portions (three press-fit portions in total), including two terminal press-fit portions and one resin press-fit portion.

[0034] For this reason, when assembling the motor cover 21 and the motor case 11, the terminal press-fit portion (terminal connection portion) and the resin press-fit portion (mechanical connection portion) are press-fitted. At this time, in order to monitor the press-fit state of the terminal press-fit portion, a measuring device is used to detect the relationship (characteristics) between the pressing load and the amount of change in pressing position (stroke) between the motor cover 21 and the motor case 11. In other words, the "load-stroke" characteristic is detected by the measuring device, and the appropriateness of the press-fit state of the terminal press-fit portion is determined based on this characteristic.

[0035] Consider a case where the height of the terminal press-fitting portion and the height of the resin press-fitting portion are the same. In this case, during the manufacturing process (assembly process) of assembling the motor cover and the motor case, the timing of press-fitting the terminal press-fitting portion and the resin press-fitting portion will be simultaneous, which may make it impossible to determine from the load whether they are properly connected.

[0036] Therefore, in this embodiment, the height dimension of the terminal press-fitting portion (the connection portion between the motor terminal 13 and the cover-side terminal 24) for electrical connection is offset from the height dimension of the resin press-fitting portion (the connection portion between the protrusion 16 and the fixed portion 25) for mechanical connection. That is, to determine whether the connection state of the electrical connection portion is proper or not, a phase is provided between the start of the electrical connection (press-fitting of the terminal component) and the start of the mechanical connection (press-fitting of the resin member). This makes it possible to determine whether the connection state is proper or not under load.

[0037] For this reason, in this embodiment, as shown in Fig. 3, the connection positions of the terminal press-fitting portions (motor terminals 13, cover-side terminals 24) are set higher than the press-fitting start points of the resin press-fitting portions (protrusions 16, fixing portions 25). This makes the timing of connection (press-fitting) of the terminal press-fitting portions (motor terminals 13, cover-side terminals 24) earlier than the timing of connection (press-fitting) of the resin press-fitting portions (protrusions 16, fixing portions 25). As a result, as shown in Fig. 4, the resin press-fitting portions (protrusions 16, fixing portions 25) are press-fitted after the terminal press-fitting portions (motor terminals 13, cover-side terminals 24) are press-fitted. Therefore, in the manufacturing process (assembly process), it can be confirmed by the load that the terminal press-fitting portions (motor terminals 13, cover-side terminals 24) and the resin press-fitting portions (protrusions 16, fixing portions 25) are properly connected.

[0038] That is, in this embodiment, the press-fit state of the motor terminal 13 and the cover-side terminal 24 is inspected based on the relationship between the "stroke, which is the amount of movement of the motor terminal 13 in the extension direction of the motor cover 21," and the "load generated during the stroke." In this case, the relationship between the load and position (stroke) when the connection is correct and the relationship between the load and position (stroke) when the connection is incorrect are obtained in advance through experiments and analyses, and a load threshold value for a predetermined stroke range is set. An example of an incorrect connection is when the motor terminal 13 slips out of the gap in the cover-side terminal 24 and rides up. Then, during the manufacturing process (assembly process), if the load within a predetermined stroke range is outside the predetermined range, the connection is determined to be incorrect, and if the load within the predetermined stroke range is within the predetermined range, the connection is determined to be correct.

[0039] Here, if the phases of "press-fitting between the protrusion 16 and the fixed portion 25, which are mechanical press-fitting points," and "press-fitting between the motor terminal 13 and the cover-side terminal 24, which are electrical press-fitting points," are close to each other, the measured load will be the sum of the respective loads, which may reduce the sensitivity of the determination. For this reason, in this embodiment, in order to accurately measure the press-fit load between the motor terminal 13 and the cover-side terminal 24, the stroke of "press-fitting between the motor terminal 13 and the cover-side terminal 24" is set to be shorter than that of "press-fitting between the protrusion 16 and the fixed portion 25," so that "press-fitting between the motor terminal 13 and the cover-side terminal 24" starts first.

[0040] Generally, the press-fit load for an electrical connection (press-fitting of terminals) is smaller than that for a mechanical connection (press-fitting for fixation). For this reason, in this embodiment, the press-fitting of the electrical connection is started with a short stroke before the press-fitting of the mechanical connection. That is, as shown in FIG. 4 , the start point of the press-fitting of the electrical connection terminals between the motor terminal 13 and the cover-side terminal 24 is set before the start point of the mechanical holding press-fitting between the protrusion 16 and the fixing portion 25. As a result, the press-fit loads of both the electrical connection parts (motor terminal 13, cover-side terminal 24) and the mechanical connection parts (protrusion 16, fixing portion 25) can be accurately detected, and assembly defects due to the load can be detected more accurately.

[0041] In order to satisfy this press-fitting order, in this embodiment, the dimensions of each part are set as follows: That is, as shown in Fig. 3A, the height from the abutment surface 28 of the motor cover 21 to the connection portion of the cover-side terminal 24 (i.e., the portion where connection with the motor terminal 13 begins) is "h1," the height from the abutment surface 17 of the motor case 11 (base 15) to the connection portion of the motor terminal 13 (i.e., the portion where connection with the cover-side terminal 24 begins) is "h2," the height from the abutment surface 17 of the motor case 11 (base 15) to the connection portion of the protrusion 16 (i.e., the portion where connection with the fixing portion 25 begins) is "h3," and the depth from the abutment surface 28 of the motor cover 21 to the connection portion of the fixing portion 25 (i.e., the portion where connection with the protrusion 16 begins) is "h4."

[0042] In this case, the following equation (1) is satisfied so that the protrusion 16 and the fixing portion 25 are press-fitted together after the motor terminal 13 and the cover-side terminal 24 are press-fitted together. That is, in the following equation (1), the left side is set to be greater than 0.

[0043]

number

[0044] For example, "h1" is 8 mm, "h2" is 5 mm, "h3" is 4 mm, and "h4" is 5 mm. In this case, after the motor terminal 13 and the cover-side terminal 24 are press-fitted by 4 mm, press-fitting of the protrusion 16 and the fixing portion 25 begins. Figure 4 shows an example of the relationship between the stroke and the load when such an assembly is performed.

[0045] As described above, in this embodiment, when the motor case 11 and the motor cover 21 are fixed to each other, the timing at which press-fitting between the motor terminal 13 and the cover-side terminal 24 begins is different from the timing at which connection between the protruding portion 16 and the fixing portion 25 begins. For this reason, in this embodiment, as shown in FIG. 3(D), the cover-side terminal 24 of the motor cover 21 is electrically press-fitted and fixed to the motor terminal 13 at a first position spaced a first length L1 from the base 15 in the direction in which the motor terminal 13 of the motor case 11 extends. In contrast, the fixing portion 25 of the motor cover 21 is press-fitted and fixed to the protruding portion 16 at a second position spaced a second length L2 different from the first length from the base 15 in the direction in which the motor terminal 13 of the motor case 11 extends. In this embodiment, the second length L2 is longer than the first length L1 (L1 <L2)。

[0046] The electric brake device 1 and the motor device 4 according to the embodiment have the configurations described above. Next, a method for manufacturing the motor device 4 will be described.

[0047] The motor device 4 comprises the following three steps. In the first step, a motor case 11 is prepared. The motor case 11 comprises a motor 12, motor terminals 13 connected to the motor 12, and a case body 14 in which the motor 12 is housed. The case body 14 has a base 15 from which the motor terminals 13 extend and a protrusion 16 that protrudes from the base 15. In the first step, such a motor case 11 is prepared.

[0048] In the second step, the motor cover 21 is prepared. The motor cover 21 has cover-side terminals 24 that are electrically fixed to the motor terminals 13 of the motor case 11, and fixing portions 25 that are press-fitted and fixed to the protrusions 16 of the case body 14 of the motor case 11. In the second step, such a motor cover 21 is prepared. The order of the first step and the second step (preparation step) may be such that the first step comes first and the second step comes later, or the second step comes first and the first step comes later, or the first step and the second step may be performed in parallel.

[0049] In the third step, the motor case 11 and the motor cover 21 are fixed to each other. In this case, the timing at which the motor terminals 13 are press-fitted into the cover-side terminals 24 from the direction in which the motor terminals 13 extend is defined as the first press-fitting timing. The timing at which the protruding portions 16 of the motor case 11 are press-fitted into the fixing portions 25 of the motor cover 21 from the direction in which the motor terminals 13 extend is defined as the second press-fitting timing. In the third step, the motor case 11 and the motor cover 21 are fixed to each other so that the first press-fitting timing and the second press-fitting timing are different.

[0050] In this case, in the embodiment, as shown in Fig. 4, the first press-fitting timing (the time when press-fitting between the motor terminal 13 and the cover-side terminal 24 starts) at which the electrical terminal connection starts is earlier than the second press-fitting timing (the time when press-fitting between the protruding portion 16 of the motor case 11 and the fixed portion 25 of the motor cover 21 starts) at which the mechanical holding connection starts. Also, in the third step, the press-fit state of the motor terminal 13 and the cover-side terminal 24 is inspected based on the relationship between the "stroke, which is the amount of movement of the motor cover 21 (the amount of movement in the extension direction of the motor terminal 13)" and the "load generated during the stroke," as shown in Fig. 4.

[0051] According to this embodiment, the accuracy of determining the connection state of the electrical connection terminals (motor terminals 13, cover-side terminals 24) due to load is improved. This improves the accuracy of detecting whether or not the electrical connection terminals are faulty or incorrectly assembled during the manufacturing process, thereby improving product quality. Furthermore, conventional structures require expensive equipment, such as non-destructive testing (X-ray inspection equipment), to check the connection state of the electrical connection terminals, which can increase investment costs. In contrast, the embodiment eliminates the need for such expensive equipment, thereby reducing costs. Furthermore, the connection state of the electrical connection terminals can be managed during the manufacturing process based on load rather than visual inspection. This eliminates the need for a structure that allows the electrical connection terminals to be observed from the outside, and the motor cover 21 can be configured by integrating the cover-side terminals 24 and the covering member (lid member) that covers them. This reduces the number of parts, thereby reducing costs and downsizing the product.

[0052] As described above, according to the embodiment, the motor cover 21 includes the cover-side terminals 24 electrically press-fitted and fixed to the motor terminals 13 of the motor case 11 at a first position spaced a first length L1 from the base 15, and the fixing portions 25 press-fitted and fixed to the protruding portions 16 of the motor case 11 at a second position spaced a second length L2 from the base 15. Therefore, when the motor case 11 and the motor cover 21 are fixed to each other, the "timing at which press-fitting between the motor terminals 13 and the cover-side terminals 24 starts (first press-fitting timing)" can be made different from the "timing at which press-fitting between the protruding portions 16 and the fixing portions 25 starts (second press-fitting timing)."

[0053] This makes it possible to determine whether each press-fit (connection) has been performed properly even when it is not possible to visually monitor the respective press-fit (connection) states, i.e., even when the respective press-fit portions (connection portions) are covered by the motor case 11 (the first housing) and the motor cover 21 (the second housing) during press-fit (connection). In other words, when connecting two parts with different functions, i.e., when connecting the "motor terminal 13 and the cover-side terminal 24 (electrical connection portions)" and the "protrusion 16 and the fixing portion 25 (mechanical connection portions)," it is possible to determine whether the press-fit state (connection state, mating state) of the electrical connection portions (motor terminal 13, cover-side terminal 24) is appropriate. This makes it possible to prevent the press-fit state (connection state, mating state) of the electrical connection portions (motor terminal 13, cover-side terminal 24) from deteriorating.

[0054] According to the embodiment, the second length L2 is longer than the first length L1. Therefore, when the motor case 11 and the motor cover 21 are fixed to each other, the press-fitting between the protrusion 16 and the fixing portion 25 can be started after the press-fitting between the motor terminal 13 and the cover-side terminal 24 has started. Moreover, according to the embodiment, the cover-side terminal 24 is an alligator-like terminal. Therefore, the cover-side terminal 24, which is an alligator-like terminal, can be press-fitted and fixed to the motor terminal 13 connected to the motor 12 (coil).

[0055] According to the embodiment, the press-fit state of the motor terminals 13 and the cover-side terminals 24 is inspected based on the relationship between the "stroke of the motor cover 21" and the "load generated during the stroke." Therefore, the appropriateness of the press-fit state (connected state, fitted state) of the electrical connection parts (motor terminals 13, cover-side terminals 24) can be determined based on the relationship between the stroke and the load.

[0056] In the embodiment, an example has been described in which the electrical connection parts (motor terminals 13, cover-side terminals 24) are press-fitted first, followed by the mechanical connection parts (protrusions 16, fixing parts 25). However, the present invention is not limited to this. For example, when the press-fit load of the electrical connection parts is high and the press-fit load of the mechanical connection parts is low, the press-fitting order may be such that the mechanical connection parts are press-fitted first, followed by the electrical connection parts, as in the modified example shown in Fig. 5. In other words, when the motor case (first housing) and the motor cover (second housing) are fixed together, the mechanical holding press-fit start point may be set before the press-fit start point of the electrical connection terminals.

[0057] That is, although not shown in the drawings, when the motor case (first housing) and the motor cover (second housing) are fixed together, the second length L2, which is the length from the base of the fixing portion, may be shorter than the first length L1, which is the length from the base of the electrical connection portion (cover-side terminal). In other words, in the third step of fixing the motor case (first housing) and the motor cover (second housing), the first press-fitting timing at which the terminal (motor terminal) is press-fitted into the electrical connection portion (cover-side terminal) may be delayed from the second press-fitting timing at which the protrusion is press-fitted into the fixing portion. Even in the case of such a modified example, deterioration of the fit between the terminal (motor terminal) and the electrical connection portion (cover-side terminal) can be suppressed.

[0058] In the embodiment, an example has been described in which the protruding portion 16 is columnar and the fixing portion 25 is cylindrical. However, this is not a limitation, and for example, the protruding portion may be cylindrical and the fixing portion may be columnar. Furthermore, the protruding portion and the fixing portion are not limited to being cylindrical or columnar, and tubes and posts of various cross-sectional shapes can be used. Furthermore, the protruding portion and the fixing portion may be other than a tube and a post, as long as they have an engagement mechanism such as a concave-convex shape that allows them to be joined (connected) to each other by mechanical press-fitting, and various mechanical joining structures (engagement structures) can be used.

[0059] In the embodiment, the cover-side terminal 24, which serves as the electrical connection portion, is described as an alligator-shaped terminal. However, this is not limiting, and the electrical connection portion may be a terminal other than an alligator-shaped terminal. That is, the terminal of the first housing (motor case) and the electrical connection portion of the second housing (motor cover) can be electrically fixed to each other, and various shapes of members (terminals) can be used as long as they are shaped so that at least a portion of them can be press-fitted by abutting without any gaps (play) when fixed (connected).

[0060] In the embodiment, the motor device has been described as an example of the motor device 4 constituting the electric brake device 1. However, the motor device is not limited to this, and can be used as a motor device constituting various electric mechanical devices other than the electric brake device, such as a motor device constituting an electric steering device.

[0061] In the embodiment, a motor device including a motor has been described as an example of the terminal connection mechanism. That is, in the embodiment, a motor device including a motor case 11 corresponding to a first housing and a motor cover 21 corresponding to a second housing has been described as an example of the terminal connection mechanism. However, the terminal connection mechanism is not limited to this, and can be used as a terminal connection mechanism for various electrically-driven devices other than motor devices, such as a solenoid device.

[0062] In this case, the terminal connection mechanism includes a first housing and a second housing. The first housing includes a terminal, a base from which the terminal extends, and a protrusion protruding from the base. The second housing includes an electrical connection portion electrically fixed to the terminal and a fixing portion press-fitted and fixed to the protrusion. In this case, the electrical connection portion is electrically press-fitted and fixed to the terminal at a first position spaced a first length from the base in the extension direction of the terminal. The fixing portion is press-fitted and fixed to the protrusion at a second position spaced a second length different from the first length from the base in the extension direction of the terminal. Then, for example, the second length is longer than the first length. Or, for example, the second length is shorter than the first length.

[0063] The terminal connecting method includes a first step of preparing a first housing, a second step of preparing a second housing, and a third step of fixing the first and second housings together. In this case, in the third step, the first and second housings are fixed together so that a "first press-fitting timing at which the terminals are press-fitted into the electrical connection portions from the terminal extension direction" and a "second press-fitting timing at which the protruding portions are press-fitted into the fixing portions from the terminal extension direction" are different. The first press-fitting timing is set, for example, earlier or later than the second press-fitting timing.

[0064] As the motor device, the manufacturing method of the motor device, the terminal connection mechanism, the terminal connection method, and the electric brake device based on the above-described embodiments, for example, the following aspects are conceivable.

[0065] A first aspect is a motor device comprising a motor case and a motor cover, wherein the motor case comprises a motor, terminals connected to the motor, and a case body in which the motor is housed, the case body having a base from which the terminals extend and a protrusion protruding from the base, and the motor cover comprises an electrical connection portion electrically press-fitted and fixed to the terminal at a first position spaced a first length from the base in the extension direction of the terminal, and a fixing portion press-fitted and fixed to the protrusion at a second position spaced a second length from the base in the extension direction of the terminal that is different from the first length.

[0066] According to this first aspect, when the motor case and the motor cover are fixed to each other, the "timing at which the press-fitting between the terminal and the electrical connection portion begins" and the "timing at which the press-fitting between the protrusion and the fixing portion begins" can be made different. This makes it possible to determine whether each press-fitting (connection) has been performed properly, even when it is not possible to visually monitor each press-fitting (connection). In other words, when connecting two parts with different functions, i.e., when connecting the "terminal and the electrical connection portion that serve as the electrical connection portion" and the "protrusion and the fixing portion that serve as the mechanical connection portion," it is possible to determine whether the press-fitting state (connection state, fitted state) of the electrical connection portion (terminal and electrical connection portion) is appropriate. This makes it possible to prevent the press-fitting state (connection state, fitted state) of the electrical connection portion (terminal and electrical connection portion) from deteriorating.

[0067] In a second aspect, the second length is longer than the first length in the first aspect. According to this second aspect, when the motor case and the motor cover are fixed to each other, press-fitting of the terminal and the electrical connection portion can be started first, and then press-fitting of the protruding portion and the fixing portion can be started.

[0068] In a third aspect, the second length is shorter than the first length in the first aspect. According to this third aspect, when the motor case and the motor cover are fixed to each other, press-fitting of the terminal and the electrical connection portion can be started after press-fitting of the protruding portion and the fixing portion has started.

[0069] As a fourth aspect, in the first aspect, the electrical connection portion is an alligator-shaped terminal. According to this fourth aspect, the alligator-shaped terminal (electrical connection portion) can be press-fitted and fixed to the terminal connected to the motor.

[0070] A fifth aspect is a method for manufacturing a motor device, comprising: a first step of preparing a motor case including a motor, terminals connected to the motor, and a case body in which the motor is housed, the case body having a base from which the terminals extend and a protrusion protruding from the base; a second step of preparing a motor cover including an electrical connection portion electrically fixed to the terminal and a fixing portion press-fitted and fixed to the protrusion; and a third step of fixing the motor case and the motor cover to each other so that a first press-fitting timing at which the terminals are press-fitted to the electrical connection portion from the extension direction of the terminals and a second press-fitting timing at which the protrusions are press-fitted to the fixing portion from the extension direction of the terminals are different.

[0071] According to the fifth aspect, when the motor case and the motor cover are fixed to each other, the "first press-fitting timing at which the press-fitting between the terminal and the electrical connection portion starts" and the "second press-fitting timing at which the press-fitting between the protrusion and the fixing portion starts" are different. This makes it possible to determine whether each press-fitting (connection) has been performed properly even when it is not possible to visually monitor each press-fitting (connection). In other words, when connecting two parts with different functions, i.e., when connecting the "terminal and the electrical connection portion that serve as the electrical connection portion" and the "protrusion and the fixing portion that serve as the mechanical connection portion," it is possible to determine whether the press-fitting state (connection state, fitted state) of the electrical connection portion (terminal and electrical connection portion) is appropriate. This makes it possible to prevent the press-fitting state (connection state, fitted state) of the electrical connection portion (terminal and electrical connection portion) from deteriorating.

[0072] As a sixth aspect, in the fifth aspect, in the third step, the first press-fitting timing is earlier than the second press-fitting timing. According to this sixth aspect, when fixing the motor case and the motor cover to each other, press-fitting between the terminal and the electrical connection portion can be started before press-fitting between the protruding portion and the fixing portion.

[0073] As a seventh aspect, in the fifth aspect, in the third step, the first press-fitting timing is later than the second press-fitting timing. According to this seventh aspect, when fixing the motor case and the motor cover to each other, press-fitting between the terminal and the electrical connection portion can be started after press-fitting between the protruding portion and the fixing portion has started.

[0074] In an eighth aspect, in the fifth aspect, in the third step, the press-fit state of the terminal and the electrical connection portion is inspected based on the relationship between a stroke, which is the amount of movement of the motor cover in the extension direction of the terminal, and a load generated during the stroke. According to this eighth aspect, the appropriateness of the press-fit state (connection state, mated state) of the electrical connection portion (terminal and electrical connection portion) can be determined based on the relationship between the stroke and the load.

[0075] A ninth aspect is a terminal connection mechanism comprising a first housing and a second housing, wherein the first housing comprises a terminal, a base from which the terminal extends, and a protrusion protruding from the base, and the second housing comprises an electrical connection portion electrically press-fitted and fixed to the terminal at a first position spaced a first length from the base in the extension direction of the terminal, and a fixing portion press-fitted and fixed to the protrusion at a second position spaced a second length from the base in the extension direction of the terminal that is different from the first length.

[0076] According to the ninth aspect, when the first housing and the second housing are fixed to each other, the timing at which the press-fitting between the terminal and the electrical connection portion starts can be made different from the timing at which the press-fitting between the protrusion and the fixing portion starts. This makes it possible to determine whether each press-fitting (connection) has been performed properly, even when it is not possible to visually monitor each press-fitting (connection). In other words, when connecting two parts with different functions, i.e., when connecting the "terminal and the electrical connection portion that serve as the electrical connection portion" and the "protrusion and the fixing portion that serve as the mechanical connection portion," it is possible to determine whether the press-fitting state (connection state, mating state) of the electrical connection portion (terminal and electrical connection portion) is appropriate. This makes it possible to prevent the press-fitting state (connection state, mating state) of the electrical connection portion (terminal and electrical connection portion) from deteriorating.

[0077] A tenth aspect is a terminal connecting method comprising: a first step of preparing a first housing having a terminal, a base from which the terminal extends, and a protrusion protruding from the base; a second step of preparing a second housing having an electrical connection portion electrically fixed to the terminal and a fixing portion press-fitted and fixed to the protrusion; and a third step of fixing the first housing and the second housing to each other so that a first press-fitting timing at which the terminal is press-fitted into the electrical connection portion from the extension direction of the terminal and a second press-fitting timing at which the protrusion is press-fitted into the fixing portion from the extension direction of the terminal are different.

[0078] According to the tenth aspect, when the first housing and the second housing are fixed to each other, the "first press-fitting timing at which the press-fitting between the terminal and the electrical connection portion starts" and the "second press-fitting timing at which the press-fitting between the protrusion and the fixing portion starts" are different. This makes it possible to determine whether each press-fitting (connection) has been performed properly even when it is not possible to visually monitor each press-fitting (connection). In other words, when connecting two parts with different functions, i.e., when connecting the "terminal and the electrical connection portion that serve as the electrical connection portion" and the "protrusion and the fixing portion that serve as the mechanical connection portion," it is possible to determine whether the press-fitting state (connection state, mated state) of the electrical connection portion (terminal and electrical connection portion) is appropriate. This makes it possible to prevent the press-fitting state (connection state, mated state) of the electrical connection portion (terminal and electrical connection portion) from deteriorating.

[0079] An eleventh aspect is an electric brake device including the motor device of the first aspect. According to this eleventh aspect, when the motor case and motor cover constituting the motor device of the electric brake device are fixed to each other, even if the press-fit (connection) of the electrical connection parts (terminals and electrical connection parts) cannot be visually monitored, it is possible to determine whether the press-fit state (connection state, fitted state) of the electrical connection parts (terminals and electrical connection parts) is appropriate. This makes it possible to prevent the press-fit state (connection state, fitted state) of the electrical connection parts (terminals and electrical connection parts) of the electric brake device (motor device) from deteriorating.

[0080] The present invention is not limited to the above-described embodiments and includes various modifications. For example, the above-described embodiments have been described in detail to clearly explain the present invention, and the present invention is not necessarily limited to those including all of the described configurations. Furthermore, it is possible to replace part of the configuration of one embodiment with the configuration of another embodiment, or to add the configuration of another embodiment to the configuration of one embodiment. Furthermore, it is possible to add, delete, or replace part of the configuration of each embodiment with other configurations.

[0081] This application claims priority to Japanese Patent Application No. 2021-099232, filed June 15, 2021. The entire disclosure of Japanese Patent Application No. 2021-099232, filed June 15, 2021, including the specification, claims, drawings, and abstract, is incorporated herein by reference in its entirety. [Explanation of symbols]

[0082] 1: electric brake device, 4: motor device (terminal connection mechanism), 11: motor case (first housing), 12: motor, 13: motor terminal (terminal), 14: case body, 15: base, 16: protrusion, 21: motor cover (second housing), 24: cover side terminal (electrical connection part), 25: fixing part

Claims

1. A motor device, the motor device comprising: A motor case and a motor cover are provided. The motor case is A motor; a terminal connected to the motor; a case body that houses the motor, the case body having a base portion from which the terminals extend and a protruding portion that protrudes from the base portion at a position different from the terminals; Equipped with The motor cover has, on its inside, an electrical connection portion that is electrically press-fitted and fixed to the terminal at a first position spaced a first distance from the base portion in an extending direction of the terminal; a fixing portion serving as a mechanical connection portion, which is configured to be press-fitted and fixed to the protrusion at a second position spaced a second length different from the first length from the base in the extending direction of the terminal, with a press-fit load higher than the press-fit load of the electrical connection portion; Equipped with The second length is longer than the first length, Motor device.

2. A motor device, the motor device comprising: A motor case and a motor cover are provided. The motor case is A motor; a terminal connected to the motor; a case body that houses the motor, the case body having a base portion from which the terminals extend and a protruding portion that protrudes from the base portion at a position different from the terminals; Equipped with The motor cover has, on its inside, an electrical connection portion that is electrically press-fitted and fixed to the terminal at a first position spaced a first distance from the base portion in an extending direction of the terminal; a fixing portion serving as a mechanical connection portion, which is configured to be press-fitted and fixed to the protrusion at a second position spaced a second length different from the first length from the base in the extending direction of the terminal, with a press-fit load lower than the press-fit load of the electrical connection portion; Equipped with The second length is shorter than the first length. Motor device.

3. 3. The motor device according to claim 1, The electrical connection portion is a crocodile-shaped terminal. Motor device.

4. A method for manufacturing a motor device, the method comprising: A motor; a terminal connected to the motor; a case body that houses the motor, the case body having a base portion from which the terminals extend and a protruding portion that protrudes from the base portion at a position different from the terminals; a first step of preparing a motor case comprising: an electrical connection portion electrically fixed to the terminal; a fixing portion that is press-fitted and fixed to the protruding portion to serve as a mechanical connection portion; a second step of preparing a motor cover having the following thereon; a third step of fixing the motor case and the motor cover to each other so that a first press-fitting timing at which the terminals are press-fitted into the electrical connection portions from the extending direction of the terminals and a second press-fitting timing at which the protruding portions are press-fitted into the fixing portions from the extending direction of the terminals with a press-fit load higher than the press-fit load of the electrical connection portions are different from each other; Equipped with In the third step, the first press-fitting timing is earlier than the second press-fitting timing. A method for manufacturing a motor device.

5. A method for manufacturing a motor device, the method comprising: A motor; a terminal connected to the motor; a case body that houses the motor, the case body having a base portion from which the terminals extend and a protruding portion that protrudes from the base portion at a position different from the terminals; a first step of preparing a motor case comprising: an electrical connection portion electrically fixed to the terminal; a fixing portion that is press-fitted and fixed to the protruding portion to serve as a mechanical connection portion; a second step of preparing a motor cover having the following thereon; a third step of fixing the motor case and the motor cover to each other so that a first press-fitting timing at which the terminals are press-fitted into the electrical connection portions from the extending direction of the terminals and a second press-fitting timing at which the protruding portions are press-fitted into the fixing portions from the extending direction of the terminals with a press-fit load lower than the press-fit load of the electrical connection portions are different from each other; Equipped with In the third step, the first press-fitting timing is later than the second press-fitting timing. A method for manufacturing a motor device.

6. 6. A method for manufacturing a motor device according to claim 4 or 5, In the third step, the press-fit state of the terminal and the electrical connection portion is inspected based on the relationship between a stroke, which is the amount of movement of the motor cover in the extension direction of the terminal, and a load generated during the stroke. A method for manufacturing a motor device.

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