Rotating electric machine and method for manufacturing the same

Abstract

The present invention provides a rotary electric machine comprising: a motor that includes a rotary shaft; and a control unit that controls the motor. The control unit comprises: a board unit including a first circuit board and a second circuit board and a holding member which is disposed between the first circuit board and the second circuit board and holds the first circuit board and the second circuit board; a heatsink disposed between the motor and the board unit such as to face the first circuit board in the axial direction of the rotary shaft; and a fastening member that secures the board unit to the heatsink. The holding member has: a base portion; a first lock portion which is connected to the base portion and locks the first circuit board from a second surface which is of the first circuit board and is on the opposite side from a first surface facing the base portion; and a second lock portion which is connected to the base portion and locks the second circuit board from a fourth surface which is of the second circuit board and is on the opposite side from a third surface facing the base portion. The fastening member passes through the board unit in the axial direction and is fastened to the heatsink.

Description

Technical Field

[0001] The present disclosure relates to a rotating electrical machine and a method for manufacturing the same.

Background Art

[0002] The rotating electrical machine disclosed in Patent Document 1 includes a motor having a rotating shaft and a control unit that controls the motor. The control unit includes a first circuit board and a second circuit board arranged side by side in the axial direction of the rotating shaft, a spacer provided between the first circuit board and the second circuit board, and a connector assembly connected to the first and second circuit boards. During the manufacture of the rotating electrical machine, in the axial direction, the connector assembly, the second circuit board, the spacer, and the first circuit board are arranged in this order, and a common fixing member is inserted through the connector assembly, the second circuit board, the spacer, and the first circuit board. By fixing the end of the common fixing member to the heat sink, the connector assembly, the second circuit board, the spacer, and the first circuit board are fixed to the heat sink.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the structure of Patent Document 1, since the first circuit board and the second circuit board cannot be fixed until they are fixed by the common fixing member, it is difficult to accurately assemble the first circuit board and the second circuit board to the heat sink. In order to improve the assembly accuracy, if the first circuit board and the second circuit board are temporarily fixed to the heat sink one by one before being fixed by the common fixing member, the manufacture of the rotating electrical machine becomes complicated and the manufacturing cost increases.

[0005] This disclosure was made to solve the above-mentioned problems, and aims to provide a rotating electric machine and a method for manufacturing the same that can assemble a first circuit board and a second circuit board with high precision, and can be manufactured easily and at low cost. [Means for solving the problem]

[0006] The rotating electric machine according to this disclosure comprises a motor having a rotating shaft and a control unit for controlling the motor, the control unit comprising a substrate unit having a first circuit board and a second circuit board and a holding member disposed between the first circuit board and the second circuit board and holding the first circuit board and the second circuit board, a heat sink disposed between the motor and the substrate unit so as to face the first circuit board in the axial direction of the rotating shaft, and a fastening member for fixing the substrate unit to the heat sink, the holding member comprising a base and a first locking portion connected to the base and locking the first circuit board from a second surface of the first circuit board opposite to the first surface facing the base and a second locking portion connected to the base and locking the second circuit board from a fourth surface of the second circuit board opposite to the third surface facing the base, the fastening member penetrates the substrate unit in the axial direction and is fastened to the heat sink.

[0007] The method for manufacturing a rotating electric machine according to this disclosure comprises a substrate unit assembly step of assembling a substrate unit by holding a first circuit board and a second circuit board with a holding member, and a substrate unit fixing step of fixing the substrate unit to the heat sink by passing a fastening member through the substrate unit in the axial direction of the motor's rotating shaft and fastening the fastening member to the heat sink. [Effects of the Invention]

[0008] According to this disclosure, a rotating electric machine and a method for manufacturing the same can be provided, which enable the assembly of a first circuit board and a second circuit board with high precision, and which can be manufactured easily and at low cost. [Brief explanation of the drawing]

[0009] [Figure 1] This is an exploded perspective view of the rotating electric machine in Embodiment 1. [Figure 2] This is a schematic cross-sectional view of the rotating electric machine in Embodiment 1. [Figure 3] This is a perspective view of the first circuit board in Embodiment 1. [Figure 4] This is a perspective view of the second circuit board in Embodiment 1. [Figure 5] This is a perspective view of the holding member in Embodiment 1. [Figure 6] This is a perspective view of the substrate unit in Embodiment 1. [Figure 7] This is a perspective view of the heatsink in Embodiment 1. [Figure 8] This is a perspective view of the connector in Embodiment 1. [Figure 9A] This is a diagram illustrating the manufacturing method of a rotating electric machine in Embodiment 1. [Figure 9B] This is a diagram illustrating the manufacturing method of a rotating electric machine in Embodiment 1. [Figure 9C] This is a diagram illustrating the manufacturing method of a rotating electric machine in Embodiment 1. [Figure 9D] This is a diagram illustrating the manufacturing method of a rotating electric machine in Embodiment 1. [Figure 9E] This is a diagram illustrating the manufacturing method of a rotating electric machine in Embodiment 1. [Figure 9F] This is a diagram illustrating the manufacturing method of a rotating electric machine in Embodiment 1. [Figure 10] This is a perspective view of the intermediate structure of the rotating electric machine in Embodiment 2, viewed from below. [Figure 11] This is a cross-sectional view along line AA in Figure 10. [Figure 12] This is a perspective view of the first circuit board in Embodiment 2. [Figure 13] This is a perspective view of the second circuit board in Embodiment 2. [Figure 14] It is a perspective view of the holding member in Embodiment 2. [Figure 15] It is a perspective view of the holding member in a modified example of Embodiment 2. [Figure 16] It is a schematic cross-sectional view of the rotating electrical machine in Embodiment 3.

Embodiments for Carrying Out the Invention

[0010] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Note that the scope of the present disclosure is not limited to the following embodiments and can be arbitrarily changed within the scope of the technical idea of the present disclosure.

[0011] Embodiment 1. FIG. 1 is an exploded perspective view of a rotating electrical machine 100 according to Embodiment 1. FIG. 2 is a schematic cross-sectional view of the rotating electrical machine 100. The rotating electrical machine 100 includes a polyphase winding type motor 1 and a control unit 2 that controls the motor 1. The control unit 2 has a first circuit board 21, a second circuit board 22, an inter-board connector 23, a holding member 24, a heat sink 25, a fastening member 26, and a connector assembly 27.

[0012] As shown in FIG. 2, the motor 1 mainly includes a rotating shaft 11, a rotor 12, a stator 13, a motor case 14, an armature winding 15, an annular wiring portion 16, a wiring terminal 17, and first and second bearings 18a and 18b.

[0013] In the following description, the direction in which the central axis O of the rotating shaft 11 in the motor 1 extends may be referred to as the axial direction. The motor 1 and the control unit 2 are arranged side by side in the axial direction. In the axial direction, the side where the control unit 2 is located may be referred to as the upper side, and the side where the motor 1 is located may be referred to as the lower side. Looking from the axial direction may be referred to as a plan view. In a plan view, the direction intersecting the central axis O may be referred to as the radial direction, and the direction circulating around the central axis O may be referred to as the circumferential direction.

[0014] The rotating shaft 11, rotor 12, and stator 13 are arranged coaxially. The rotating shaft 11 has an input end 11a located at the top and an output end 11b located at the bottom. The drive object (for example, the steering system of a vehicle) is connected to the output end 11b. The rotor 12 is fixed to the rotating shaft 11. Multiple pairs of permanent magnets (not shown) are arranged on the outer circumferential surface of the rotor 12. These permanent magnets constitute the field poles. The stator 13 is provided so as to surround the outer circumference of the rotor 12. An air gap is formed between the outer surface of the rotor 12 and the inner surface of the stator 13. The air gap is formed along the entire circumference in the circumferential direction.

[0015] The motor case 14 houses the rotating shaft 11, rotor 12, and stator 13. The motor case 14 has a cylindrical portion 14a and a bottom portion 14b. The cylindrical portion 14a covers the stator 13 from the outer circumference. The stator 13 is fixed to the inner surface of the cylindrical portion 14a by shrink-fitting or press-fitting. The bottom portion 14b covers the lower end of the cylindrical portion 14a. In the center of the bottom portion 14b in a plan view, an output-side shaft through-hole 14c is formed through which the rotating shaft 11 is inserted. The upper end of the cylindrical portion 14a is covered by the heat sink 25 of the control unit 2.

[0016] The armature winding 15 is wound around the stator 13. The armature winding 15 comprises a U-phase winding, a V-phase winding, and a W-phase winding. The annular wiring section 16 is positioned above the stator 13. The annular wiring section 16 is positioned in close proximity to the armature winding 15. The annular wiring section 16 is connected to the end of the armature winding 15 by TIG welding or the like. The wiring terminal 17 extends upward from the annular wiring section 16, passing through the heat sink 25. The wiring terminal 17 is electrically connected to the end of the armature winding 15 via the annular wiring section 16. More specifically, the wiring terminal 17 consists of three conductors, each electrically connected to the end of the U-phase winding, the V-phase winding, and the W-phase winding of the armature winding 15. The upper end of the wiring terminal 17 is connected to the first circuit board 21 of the control unit 2.

[0017] The input end 11a of the rotating shaft 11 is inserted through a first shaft through hole 61 formed in the heat sink 25. The output end 11b of the rotating shaft 11 is inserted through an output-side shaft through hole 14c formed in the bottom portion 14b. A first bearing 18a is provided in the first shaft through hole 61. A second bearing 18b is provided in the output-side shaft through hole 14c. The first bearing 18a and the second bearing 18b rotatably support the rotating shaft 11.

[0018] A sensor magnet 19 is attached to the input end 11a of the rotating shaft 11. The sensor magnet 19 is fixed to the axially facing end face of the input end 11a by press-fitting. The sensor magnet 19 comprises one or more pairs of permanent magnets. The sensor magnet 19 rotates together with the rotating shaft 11. Therefore, the magnetic field generated by the sensor magnet 19 changes as the rotating shaft 11 rotates.

[0019] The control unit 2 controls the motor 1. In the axial direction, the second circuit board 22, the retaining member 24, the first circuit board 21, and the heat sink 25 are arranged in this order from top to bottom. The first circuit board 21, the second circuit board 22, the inter-board connector 23, and the retaining member 24 constitute the board unit 20.

[0020] The control unit 2 is covered from above by a cover 70. The cover 70 is attached to a heat sink 25. The circuit board unit 20 (first circuit board 21, second circuit board 22, inter-board connector 23, and retaining member 24) is housed in the space enclosed by the cover 70 and the heat sink 25.

[0021] The first circuit board 21 is positioned between the holding member 24 and the heat sink 25 in the axial direction. The first circuit board 21 has a first surface 21a and a second surface 21b. The first surface 21a is the upper surface of the first circuit board 21, and the second surface 21b is the lower surface of the first circuit board 21.

[0022] An inverter circuit for driving the motor 1 is mounted on the first circuit board 21. The inverter circuit is composed of electronic components such as switching elements, shunt resistors, and smoothing capacitors. Of these electronic components, the heat-generating electronic component 28, which generates heat when the motor 1 is driven, is preferably placed on the second surface 21b of the first circuit board 21. The electronic component 28 is in contact with the upper surface of the heat sink 25 via thermal grease 29. The heat generated from the electronic component 28 is dissipated to the heat sink 25 via the thermal grease 29. The electronic component 28 may also be placed on the first surface 21a of the first circuit board 21.

[0023] Figure 3 is a perspective view of the first circuit board 21 from above. In the following description, as shown in Figure 3, one direction in the plane along the first surface 21a of the first circuit board 21 is referred to as the first direction D1, and the direction perpendicular to the first direction D1 in the above plane is referred to as the second direction D2. The first direction D1 and the second direction D2 are perpendicular to the axial direction.

[0024] The first circuit board 21 is provided with a second shaft through hole 31, a motor terminal connection hole 32 (motor connection part), a first fastening through hole 33, a first positioning through hole 34, a connector terminal connection hole 35 (first connector connection part), and a connector positioning through hole 37.

[0025] The second shaft through-hole 31 penetrates the first circuit board 21 in the axial direction. The second shaft through-hole 31 is positioned to overlap with the output side shaft through-hole 14c in a plan view. The input end 11a of the rotating shaft 11 is inserted through the second shaft through-hole 31.

[0026] The motor terminal connection holes 32 penetrate the first circuit board 21 in the axial direction. The motor terminal connection holes 32 are provided at the end of the first circuit board 21 in the second direction D2. Three motor terminal connection holes 32 are arranged side by side in the first direction D1. The three motor terminal connection holes 32 are connected to the three conductors of the wiring terminal 17, respectively.

[0027] The first fastening through-hole 33 penetrates the first circuit board 21 in the axial direction. The first fastening through-hole 33 is provided on the outer edge of the first circuit board 21. In this embodiment, a plurality of first fastening through-holes 33 are provided on the first circuit board 21 at both ends in the first direction D1 and at both ends in the second direction D2. A fastening member 26 is inserted through the first fastening through-hole 33.

[0028] The first positioning through-hole 34 penetrates the first circuit board 21 in the axial direction. The first positioning through-hole 34 is provided on the outer edge of the first circuit board 21. In this embodiment, a pair of first positioning through-holes 34 are provided at both ends of the first circuit board 21 in the second direction D2. The first positioning projection 55 of the retaining member 24, which will be described later, is inserted through the first positioning through-hole 34.

[0029] The connector terminal connection holes 35 penetrate the first circuit board 21 in the axial direction. The connector terminal connection holes 35 are provided at one end of the first circuit board 21 in the first direction D1. In this embodiment, a plurality of connector terminal connection holes 35 are arranged in a line in the second direction D2. Press-fit terminals 74 of the connector assembly 27, which will be described later, are connected to the connector terminal connection holes 35.

[0030] The connector positioning through-hole 37 penetrates the first circuit board 21 in the axial direction. The connector positioning through-hole 37 is provided at one end of the first circuit board 21 in the first direction D1. In this embodiment, a pair of connector positioning through-holes 37 are provided so as to be located on both sides of a plurality of connector terminal connection holes 35 in the second direction D2 when viewed from the first direction D1. The connector positioning projection 75 of the connector assembly 27, which will be described later, is inserted through the connector positioning through-hole 37.

[0031] Returning to Figure 2, the second circuit board 22 is positioned above the first circuit board 21. The second circuit board 22 has a third surface 22a and a fourth surface 22b. The third surface 22a is the lower surface of the second circuit board 22, and the fourth surface 22b is the upper surface of the second circuit board 22.

[0032] The second circuit board 22 has a control circuit mounted on it that controls the drive of the motor 1. The control circuit consists of a microcontroller that calculates the drive control of the motor 1, a drive circuit used to control the switching elements, and the like.

[0033] A rotation sensor 30 is mounted on the third surface 22a of the second circuit board 22. The rotation sensor 30 is a magnetic sensor such as a magnetoresistive sensor (MR sensor) or a Hall sensor. The rotation sensor 30 is positioned coaxially with a sensor magnet 19 attached to the rotating shaft 11. The sensor magnet 19 and the rotation sensor 30 face each other with a gap in between. The rotation sensor 30 detects changes in the magnetic field from the permanent magnet of the sensor magnet 19, which rotates with the rotating shaft 11, and converts this into an electrical signal. The rotation angle of the rotating shaft 11 is detected by the sensor magnet 19 and the rotation sensor 30. Note that a resolver, optical sensor, etc. may be used as the rotation sensor 30.

[0034] Figure 4 is a perspective view of the second circuit board 22 from above. As shown in Figure 4, the second circuit board 22 is provided with a second fastening through hole 41, a second positioning through hole 42, and a notch 43.

[0035] The second fastening through-hole 41 penetrates the second circuit board 22 in the axial direction. The second fastening through-hole 41 is provided on the outer edge of the second circuit board 22. In this embodiment, a plurality of second fastening through-holes 41 are arranged in a position that overlaps with a plurality of first fastening through-holes 33 in a plan view. A fastening member 26 is inserted through the second fastening through-hole 41.

[0036] The second positioning through-hole 42 penetrates the second circuit board 22 in the axial direction. The second positioning through-hole 42 is provided on the outer edge of the second circuit board 22. In this embodiment, the pair of second positioning through-holes 42 are positioned to overlap with the pair of first positioning through-holes 34 in a plan view. Note that the first positioning through-holes 34 and the second positioning through-holes 42 may be positioned at different locations in a plan view. The second positioning projection 56 of the retaining member 24, which will be described later, is inserted through the second positioning through-hole 42.

[0037] The notches 43 are provided so as to be recessed inward from the edge of the second circuit board 22 in the second direction D2. In this embodiment, a pair of notches 43 are provided at both ends of the second circuit board 22 in the second direction D2. The notches 43 are formed in a position that overlaps with the motor terminal connection holes 32 in a plan view. When the board unit 20 is viewed from the second circuit board 22 side along the axial direction, the notches 43 expose the motor terminal connection holes 32.

[0038] The length of the second circuit board 22 in the first direction D1 is shorter than the length of the first circuit board 21 in the first direction D1. When the board unit 20 is viewed from the second circuit board 22 side along the axial direction, one end of the first circuit board 21 in the first direction D1 (connector terminal connection hole 35) is exposed from the second circuit board 22.

[0039] Returning to Figure 2, the board-to-board connector 23 is positioned axially between the first circuit board 21 and the second circuit board 22. The board-to-board connector 23 electrically connects the inverter circuit of the first circuit board 21 and the control circuit of the second circuit board 22. The board-to-board connector 23 consists of a male connector mounted on the first circuit board 21 and a female connector mounted on the second circuit board 22. By mating the male connector and the female connector with each other, the first circuit board 21 and the second circuit board 22 are electrically connected via the board-to-board connector 23. Note that a bent board may be used as the board-to-board connector 23, or a connector with a press-fit shape at the tip of the terminal may be used.

[0040] The holding member 24 is positioned between the first circuit board 21 and the second circuit board 22 in the axial direction. The circuit board unit 20 is assembled by holding the first circuit board 21 and the second circuit board 22 with the holding member 24 while the first circuit board 21 and the second circuit board 22 are electrically connected by the inter-board connector 23.

[0041] Figure 5 is a perspective view of the holding member 24 from above. Figure 6 is a perspective view of the substrate unit 20 from below. As shown in Figure 5, the retaining member 24 includes a base 51, a first locking portion 52, a second locking portion 53, a spacer 54, a first positioning projection 55, a second positioning projection 56, and a load transmission portion 57.

[0042] The base portion 51 is frame-shaped with an inner space. The members 52 to 57 of the holding member 24 are connected to the base portion 51. Electronic components mounted on the first circuit board 21 and the second circuit board 22, including the rotation sensor 30, are housed in the inner space of the base portion 51. This allows the inner space of the base portion 51 to be used to house the electronic components, thereby enabling miniaturization of the board unit 20.

[0043] The first locking portion 52 locks the first circuit board 21 from the second surface 21b of the first circuit board 21 (i.e., the surface of the first circuit board 21 opposite to the first surface 21a facing the base portion 51). As shown in Figure 6, a plurality of first locking portions 52 are provided so as to surround the first circuit board 21. The first locking portion 52 has a first projection 52a extending downward from the base portion 51 (i.e., toward the first circuit board 21) and a first locking claw 52b located at the tip of the first projection 52a. The first locking claw 52b has a first locking surface facing upward. The first circuit board 21 is fixed in the axial direction to the holding member 24 when the first locking surface of the first locking claw 52b abuts against the second surface 21b of the first circuit board 21.

[0044] The second locking portion 53 locks the second circuit board 22 from the fourth surface 22b of the second circuit board 22 (i.e., the surface of the second circuit board 22 opposite to the third surface 22a facing the base portion 51). As shown in Figure 6, a plurality of second locking portions 53 are provided so as to surround the second circuit board 22. The second locking portion 53 has a second projection 53a extending upward from the base portion 51 (i.e., toward the second circuit board 22) and a second locking claw 53b located at the tip of the second projection 53a. The second locking claw 53b has a second locking surface facing downward. The second circuit board 22 is fixed in the axial direction to the holding member 24 by the second locking surface of the second locking claw 53b contacting the fourth surface 22b of the second circuit board 22.

[0045] The spacer 54 is cylindrical and extends in the axial direction. In this embodiment, multiple spacers 54 are arranged in positions that overlap with multiple first fastening through holes 33 in a plan view. One axial end of the spacer 54 abuts against the first circuit board 21, and the other axial end of the spacer 54 abuts against the second circuit board 22. The spacer 54 ensures a gap between the first circuit board 21 and the second circuit board 22. The spacer 54 has a third fastening through hole 54a that penetrates the spacer 54 in the axial direction. A fastening member 26 is inserted through the third fastening through hole 54a. When the substrate unit 20 is assembled, the second fastening through-hole 41 of the second circuit board 22, the third fastening through-hole 54a of the retaining member 24, and the first fastening through-hole 33 of the first circuit board 21 are arranged coaxially in this order from above. The second fastening through-hole 41, the third fastening through-hole 54a, and the first fastening through-hole 33 are in communication with each other. Hereinafter, these second fastening through-hole 41, third fastening through-hole 54a, and first fastening through-hole 33 will be collectively referred to as the fastening through-holes of the substrate unit 20.

[0046] The first positioning projection 55 is cylindrical and extends in the axial direction. In this embodiment, a pair of first positioning projections 55 are provided corresponding to a pair of first positioning through holes 34. The first positioning projection 55 extends downward from the base 51. The first positioning projection 55 is inserted through the first positioning through hole 34. The first positioning projection 55 positions the first circuit board 21 relative to the holding member 24. The height of the first positioning projection 55 is greater than the height of the first locking portion 52. That is, the tip of the first positioning projection 55 is located below the tip of the first locking portion 52. Furthermore, the first positioning projection 55 is fitted into the fitting hole 64 of the heat sink 25, which will be described later. This positions the substrate unit 20 relative to the heat sink 25.

[0047] The second positioning projection 56 is cylindrical and extends in the axial direction. In this embodiment, a pair of second positioning projections 56 are provided corresponding to a pair of second positioning through holes 42. The second positioning projection 56 extends upward from the base 51. The second positioning projection 56 is inserted through the second positioning through hole 42. The second positioning projection 56 positions the second circuit board 22 relative to the holding member 24. The height of the second positioning projection 56 is greater than the height of the second locking portion 53. That is, the tip of the second positioning projection 56 is located above the tip of the second locking portion 53. In this embodiment, the first positioning projection 55 and the second positioning projection 56 are positioned to overlap in a plan view. However, the first positioning projection 55 and the second positioning projection 56 may be positioned at different locations in a plan view.

[0048] The load transmission section 57 is positioned in a location that overlaps with the heat dissipation grease 29 in a plan view. The load transmission section 57 has a first contact section 57a ​​that contacts the first circuit board 21, a second contact section 57b that contacts the second circuit board 22, and a connecting section 57c that connects the first contact section 57a ​​and the second contact section 57b. The first contact section 57a ​​is a projection provided on the lower surface of the base section 51. The second contact section 57b is a projection provided on the upper surface of the base section 51. The connecting section 57c is part of the base section 51. The load applied to the second circuit board 22 during the manufacture of the rotating electric machine 100 is transmitted to the first circuit board 21 via the load transmission section 57.

[0049] Returning to Figure 2, the heat sink 25 is positioned axially between the stator 13 and the circuit board unit 20 (first circuit board 21). The heat sink 25 is fitted into the cylindrical portion 14a of the motor case 14. The heat sink 25 covers the stator 13 from above. The heat sink 25 separates the space housing the rotor 12 and stator 13 of the motor 1 from the space housing the circuit board unit 20 of the control unit 2.

[0050] Figure 7 is a perspective view of the heat sink 25 from above. As shown in Figure 7, the heat sink 25 is provided with a first shaft through hole 61, a motor terminal through hole 62, a fastening hole 63, and a fitting hole 64.

[0051] The first shaft through-hole 61 penetrates the heat sink 25 in the axial direction. The first shaft through-hole 61 is positioned to overlap with the output-side shaft through-hole 14c in a plan view. The input end 11a of the rotating shaft 11 is inserted through the first shaft through-hole 61.

[0052] The motor terminal through-holes 62 penetrate the heat sink 25 in the axial direction. The motor terminal through-holes 62 are located at the end of the heat sink 25 in the second direction D2. Three motor terminal through-holes 62 are arranged side by side in the first direction D1. The three motor terminal through-holes 62 are positioned to overlap with the three motor terminal connection holes 32 in a plan view. The three conductors of the wiring terminal 17 are inserted through each of the three motor terminal through-holes 62. In a plan view, the size of the motor terminal through-holes 62 is larger than the size of the wiring terminal 17. Therefore, contact between the wiring terminal 17 and the motor terminal through-holes 62 is prevented when the wiring terminal 17 is inserted through the motor terminal through-holes 62.

[0053] The fastening holes 63 are provided on the outer edge of the heat sink 25. The fastening holes 63 are recessed downward from the upper surface of the heat sink 25. In this embodiment, multiple fastening holes 63 are arranged in positions that overlap with multiple first fastening through holes 33 in a plan view. Fastening members 26 are fastened to the fastening holes 63.

[0054] The fitting holes 64 are provided on the outer edge of the heat sink 25. The fitting holes 64 are recessed downward from the upper surface of the heat sink 25. In this embodiment, the pair of fitting holes 64 are positioned to overlap with the pair of first positioning through holes 34 in a plan view. The first positioning projections 55 are fitted into the fitting holes 64.

[0055] The fastening members 26 are used to fix the substrate unit 20 to the heat sink 25. In this embodiment, multiple fastening members 26 are provided corresponding to multiple fastening through holes in the substrate unit 20. The fastening members 26 are inserted from the second circuit board 22 side through the fastening through holes in the substrate unit 20 and fastened to the fastening holes 63 in the heat sink 25. That is, the fastening members 26 penetrate the substrate unit 20 in the axial direction and are fastened to the heat sink 25.

[0056] The fastening member 26 is, for example, a screw. The fastening member 26 has a head that abuts against the second circuit board 22 and a shaft that extends axially from the head. The shaft of the fastening member 26 is inserted through a fastening through hole in the board unit 20 and fastened to the fastening hole 63 of the heat sink 25. In plan view, the outer shape of the head of the fastening member 26 is substantially the same as the outer shape of the spacer 54. Furthermore, it is preferable that the material of the fastening member 26 is the same as the material of the spacer 54. In this case, it is possible to suppress changes in the fastening force of the fastening member 26 to the first circuit board 21 and the second circuit board 22 due to temperature changes.

[0057] The connector assembly 27 electrically connects the rotating electric machine 100 to an external power supply and sensors, etc. The connector assembly 27 is located on the underside of the heat sink 25. The connector assembly 27 faces the first circuit board 21 via the heat sink 25. The connector assembly 27 is connected to the first circuit board 21. In this embodiment, the connector assembly 27 is located below the first circuit board 21, but the connector assembly 27 may also be located above the first circuit board 21.

[0058] Figure 8 is a perspective view of the connector assembly 27. As shown in Figure 8, the connector assembly 27 includes a power terminal 71, a signal terminal 72, a connector holding portion 73, and a connector positioning projection 75.

[0059] The power terminal 71 is connected to an external power supply. The signal terminal 72 is connected to an external sensor, etc. Power from the external power supply is supplied to the first circuit board 21 via the power terminal 71. Various signals from the external sensor, etc. are supplied to the first circuit board 21 via the signal terminal 72. The power terminal 71 and the signal terminal 72 are held by the connector holding part 73.

[0060] The ends of the power terminal 71 and signal terminal 72 on the first circuit board 21 side are press-fit terminals 74 (first press-fit terminals). The press-fit terminals 74 extend from the connector holding portion 73 toward the first circuit board 21. Multiple press-fit terminals 74 are press-fitted into multiple connector terminal connection holes 35. The press-fit terminals 74 and the connector terminal connection holes 35 are electrically connected when the press-fit terminals 74 come into contact with a conductive layer formed on the inner surface of the connector terminal connection holes 35.

[0061] The connector positioning projection 75 is formed in a cylindrical shape. In this embodiment, a pair of connector positioning projections 75 are provided corresponding to a pair of connector positioning through holes 37. The connector positioning projection 75 extends from the connector holding portion 73 toward the first circuit board 21. The connector positioning projection 75 is inserted through the connector positioning through hole 37. The connector positioning projection 75 positions the connector assembly 27 relative to the first circuit board 21. The height of the connector positioning projection 75 is greater than the height of the press-fit terminal 74. That is, the tip of the connector positioning projection 75 is located toward the first circuit board 21 than the tip of the press-fit terminal 74.

[0062] Next, a method for manufacturing the rotating electric machine 100 will be described. The method for manufacturing the rotating electric machine 100 according to this embodiment comprises a substrate unit assembly step, a substrate unit fixing step, a connector mounting step, and a cover mounting step.

[0063] In the circuit board unit assembly process, the first circuit board 21 and the second circuit board 22 are held by the holding member 24 to assemble the circuit board unit 20. Specifically, as shown in Figure 9A, the first positioning projection 55 is inserted through the first positioning through hole 34, and the first locking portion 52 locks the first circuit board 21 from its second surface 21b. This fixes the first circuit board 21 to the holding member 24. The height of the first positioning projection 55 is greater than the height of the first locking portion 52. Therefore, the first circuit board 21 can be locked by the first locking portion 52 while it is positioned relative to the holding member 24 by the first positioning projection 55. The second positioning projection 56 is inserted through the second positioning through hole 42, and the second locking portion 53 locks the second circuit board 22 from its fourth surface 22b. This fixes the second circuit board 22 to the holding member 24. The height of the second positioning projection 56 is greater than the height of the second locking portion 53. Therefore, the second circuit board 22 can be locked by the second locking portion 53 while it is positioned relative to the holding member 24 by the second positioning projection 56. Furthermore, by mating the male connector of the inter-board connector 23 mounted on the first circuit board 21 with the female connector of the inter-board connector 23 mounted on the second circuit board 22, the first circuit board 21 and the second circuit board 22 are electrically connected via the inter-board connector 23.

[0064] In the substrate unit fixing process, the substrate unit 20 is fixed to the heat sink 25 by fastening members 26. Specifically, as shown in Figure 9B, the circuit board unit 20 is arranged so that the first circuit board 21 and the heat sink 25 face each other. The heat sink 25 is pre-attached to the motor 1. As shown in Figure 9C, the substrate unit 20 is placed on the upper surface of the heat sink 25. At this time, the substrate unit 20 is positioned relative to the heat sink 25 by fitting the first positioning projection 55 into the fitting hole 64 of the heat sink 25 (see Figure 9B). The wiring terminals 17 are inserted through the motor terminal connection holes 32. In addition, a load is applied to the second circuit board 22 towards the heat sink 25 (direction of the arrow in Figure 9C) using a jig or the like, pressing the second circuit board 22 toward the heat sink 25. The load applied to the second circuit board 22 is transmitted to the first circuit board 21 via the load transmission unit 57. As a result, the first circuit board 21 is also pressed toward the heat sink 25, and the thermal grease 29 applied between the heat sink 25 and the electronic components 28 mounted on the first circuit board 21 is spread out. Subsequently, as shown in Figure 9D, the fastening member 26 is inserted from the second circuit board 22 side through the fastening through hole of the board unit 20 and fastened to the fastening hole 63 of the heat sink 25. The wiring terminal 17 and the motor terminal connection hole 32 are electrically connected by soldering or the like. At this time, since the second circuit board 22 is provided with a notch 43, it is possible to prevent the connecting tool used to connect the wiring terminal 17 to the motor terminal connection hole 32 from interfering with the second circuit board 22.

[0065] In the connector mounting process, the connector assembly 27 is connected to the first circuit board 21. Specifically, as shown in Figure 9E, the intermediate structure of the rotating electric machine 100 is inverted vertically after the substrate unit fixing process. The connector assembly 27 is positioned opposite the second surface 21b of the first circuit board 21. The connector positioning projection 75 (see Figure 7) is inserted through the connector positioning through hole 37 of the first circuit board 21. A load is applied to the connector assembly 27 toward the first circuit board 21 (in the direction of the arrow in Figure 9E), and the press-fit terminal 74 is press-fitted into the connector terminal connection hole 35 of the first circuit board 21. The height of the connector positioning projection 75 is greater than the height of the press-fit terminal 74. Therefore, with the connector assembly 27 positioned relative to the first circuit board 21 by the connector positioning projection 75, the press-fit terminal 74 can be press-fitted into the connector terminal connection hole 35. Here, when the press-fit terminal 74 is pressed into the connector terminal connection hole 35, a pressing force is applied to the first circuit board 21. By installing a receiving jig (not shown) on the first surface 21a of the first circuit board 21, the pressing force applied to the first circuit board 21 can be absorbed by the receiving jig. Therefore, distortion of the first circuit board 21 can be suppressed, and connection failure of the press-fit terminal 74 due to insufficient insertion depth into the connector terminal connection hole 35 can be prevented. Subsequently, the connector assembly 27 is screw-fixed to the heat sink 25 using the second fastening member 77.

[0066] As shown in Figure 9F, in the cover mounting process, the intermediate structure of the rotating electric machine 100 is inverted again after the connector mounting process. The cover 70 is then assembled onto the heat sink 25 from above. This completes the rotating electric machine 100.

[0067] As described above, the rotating electric machine 100 according to this embodiment includes a motor 1 having a rotating shaft 11 and a control unit 2 for controlling the motor 1. The control unit 2 includes a substrate unit 20 having a first circuit board 21 and a second circuit board 22, and a holding member 24 disposed between the first circuit board 21 and the second circuit board 22 for holding the first circuit board 21 and the second circuit board 22, a heat sink 25 disposed between the motor 1 and the substrate unit 20 so as to face the first circuit board 21 in the axial direction, and a fastening member 26 for fixing the substrate unit 20 to the heat sink 25. The holding member 24 has a base portion 51, a first locking portion 52 connected to the base portion 51 that locks the first circuit board 21 from the second surface 21b of the first circuit board 21, and a second locking portion 53 connected to the base portion 51 that locks the second circuit board 22 from the fourth surface 22b of the second circuit board 22. The fastening member 26 penetrates the substrate unit 20 in the axial direction and is fastened to the heat sink 25.

[0068] Furthermore, the manufacturing method of the rotating electric machine 100 according to this embodiment includes a substrate unit assembly step of assembling a substrate unit 20 by holding a first circuit board 21 and a second circuit board 22 with a holding member 24, and a substrate unit fixing step of fixing the substrate unit 20 to the heat sink 25 by passing a fastening member 26 through the substrate unit 20 in the axial direction and fastening the fastening member 26 to the heat sink 25.

[0069] According to this rotating electric machine 100 or method for manufacturing the rotating electric machine 100, the board unit 20 is assembled by holding the first circuit board 21 and the second circuit board 22 with the holding member 24. Then, by fixing the board unit 20 to the heat sink 25 with the fastening member 26, the first circuit board 21 and the second circuit board 22 can be assembled to the heat sink 25 at once and with high precision. Since it is not necessary to assemble the circuit boards 21 and 22 one by one, the manufacturing of the rotating electric machine 100 becomes easier. In addition, since the manufacturing line for the rotating electric machine 100 can be shared with the manufacturing line for a rotating electric machine in which the control unit is composed of a single circuit board, manufacturing costs can be reduced. Furthermore, for example, if the rotation sensor 30 that detects the rotation angle of the rotating shaft 11 is mounted on the first circuit board 21 or the second circuit board 22, the detection accuracy of the rotation sensor 30 may decrease if the positions of the first circuit board 21 and the second circuit board 22 with respect to the rotating shaft 11 are misaligned. Since the first circuit board 21 and the second circuit board 22 can be assembled to the heat sink 25 with high precision, misalignment of the positions of the first circuit board 21 and the second circuit board 22 with respect to the rotating shaft 11 can be prevented, and thus a decrease in the detection accuracy of the rotation sensor 30 can be prevented.

[0070] Furthermore, the retaining member 24 is connected to the base 51, extends axially, and has a spacer 54 that contacts the first circuit board 21 and the second circuit board 22. The fastening member 26 is inserted through the spacer 54. With this configuration, the spacer 54 can be used to ensure a gap between the first circuit board 21 and the second circuit board 22. Therefore, the manufacturing of the rotating electric machine 100 becomes easier. In addition, the spacer 54 can be used to fix the board unit 20 to the heat sink 25. Therefore, since there is no need to separately provide fixing bosses or the like for fixing the board unit 20 to the heat sink 25, the increase in the number of components can be suppressed, and the reduction in the mounting area of ​​electronic components on the first circuit board 21 and the second circuit board 22 can be suppressed.

[0071] Furthermore, the holding member 24 has a first positioning projection 55 connected to the base 51, which penetrates the first circuit board 21 in the axial direction and is inserted into the heat sink 25, and a second positioning projection 56 connected to the base 51, which penetrates the second circuit board 22 in the axial direction. With this configuration, the first positioning projection 55 and the second positioning projection 56 allow the first circuit board 21 and the second circuit board 22 to be positioned relative to the heat sink 25. Therefore, the first circuit board 21 and the second circuit board 22 can be assembled to the heat sink 25 with greater precision.

[0072] Furthermore, electronic components 28 are mounted on the first circuit board 21, and thermal grease 29 is provided between the heat sink 25 and the electronic components 28. The holding member 24 is positioned to overlap with the thermal grease 29 in a plan view and further has a load transmission portion 57 that contacts the first circuit board 21 and the second circuit board 22. With this configuration, the load applied to the second circuit board 22 during the manufacturing of the rotating electric machine 100 is transmitted to the first circuit board 21 via the load transmission unit 57, thereby spreading the heat dissipation grease 29 provided between the heat sink 25 and the electronic component 28.

[0073] The motor 1 also includes a rotor 12 fixed to a rotating shaft 11, a stator 13 positioned on the outer circumference of the rotor 12, an armature winding 15 wound around the stator 13, and wiring terminals 17 that are electrically connected to the armature winding 15 and connected to the first circuit board 21. The first circuit board 21 has motor terminal connection holes 32 to which the wiring terminals 17 are connected. The second circuit board 22 has a notch 43 that exposes the motor terminal connection holes 32 when the board unit 20 is viewed from the second circuit board 22 side along the axial direction. With this configuration, for example, a connecting tool for connecting the wiring terminal 17 to the motor terminal connection hole 32 can be brought close to the connection point between the wiring terminal 17 and the motor terminal connection hole 32 via the notch 43. Therefore, the connection between the wiring terminal 17 and the motor terminal connection hole 32 can be easily made via the notch 43. Consequently, the manufacturing of the rotating electric machine 100 becomes easier.

[0074] Furthermore, when viewed from the axial direction, the outer shape of the head of the fastening member 26 is substantially the same as the outer shape of the spacer 54. This configuration allows the spacer 54 to reliably absorb the force generated when fastening the fastening member 26, while minimizing the increase in the space required for the head of the fastening member 26.

[0075] The control unit 2 further includes a connector assembly 27 having press-fit terminals 74 connected to the first circuit board 21. The first circuit board 21 has a connector terminal connection hole 35 provided at one end of the first direction D1, to which the press-fit terminals 74 are connected. When the board unit 20 is viewed axially from the second circuit board 22 side, the length of the second circuit board 22 in the first direction D1 is shorter than the length of the first circuit board 21 in the first direction D1, so that one end of the first circuit board 21 in the first direction D1 is exposed from the second circuit board 22. With this configuration, the connector assembly 27 can be easily connected to the first circuit board 21 using the press-fit terminals 74. Therefore, the manufacturing of the rotating electric machine 100 becomes easier. Furthermore, when connecting the press-fit terminal 74 to the connector terminal connection hole 35, a pressing force is applied to one end of the first circuit board 21 in the first direction D1. Since the aforementioned end of the first circuit board 21 is exposed from the second circuit board 22, a support jig for supporting the aforementioned end can be easily installed on the first circuit board 21. By receiving the pressing force applied to the first circuit board 21 with the support jig, distortion of the first circuit board 21 can be suppressed. In addition, poor connection of the press-fit terminal 74 due to insufficient insertion depth into the connector terminal connection hole 35 can be prevented.

[0076] Furthermore, the connector assembly 27 has a connector positioning projection 75 that is inserted into the first circuit board 21. With this configuration, the connector assembly 27 is positioned relative to the first circuit board 21 by the connector positioning projection 75, so that the press-fit terminal 74 can be reliably connected through the connector terminal connection hole 35.

[0077] Furthermore, the tip of the connector positioning projection 75 is located closer to the first circuit board 21 than the tip of the press-fit terminal 74. With this configuration, the connector assembly 27 is positioned relative to the first circuit board 21 by the connector positioning projection 75, and the press-fit terminal 74 can be connected to the connector terminal connection hole 35. Therefore, the press-fit terminal 74 can be reliably connected to the connector terminal connection hole 35.

[0078] Furthermore, the board unit 20 also includes an inter-board connector 23 that electrically connects the first circuit board 21 and the second circuit board 22. With this configuration, the first circuit board 21 and the second circuit board 22 can be easily electrically connected by the inter-board connector 23.

[0079] Embodiment 2. Next, the rotating electric machine 100A according to Embodiment 2 will be described. The rotating electric machine 100A according to this embodiment has the same basic configuration as Embodiment 1, so the differences will be the main points to be explained.

[0080] Figure 10 is a perspective view of the intermediate structure of the rotating electric machine 100A, seen from below. Figure 11 is a cross-sectional view of AA in Figure 10. This embodiment differs from Embodiment 1 in that the connector assembly 27A is connected to the first circuit board 21A and the second circuit board 22A.

[0081] As shown in Figures 10 and 11, the connector assembly 27A has, instead of the press-fit terminal 74, a first press-fit terminal 81 connected to the first circuit board 21A and a second press-fit terminal 82 connected to the second circuit board 22A. The first press-fit terminal 81 is positioned in the center of the connector assembly 27A in the second direction D2. The second press-fit terminal 82 is positioned on both sides of the first press-fit terminal 81 in the second direction D2. The height of the second press-fit terminal 82 is greater than the height of the first press-fit terminal 81. That is, the tip of the second press-fit terminal 82 is positioned closer to the second circuit board 22A than the tip of the first press-fit terminal 81.

[0082] In this embodiment, the length of the second circuit board 22A in the first direction D1 is approximately the same as the length of the first circuit board 21A in the first direction D1. In a plan view, the second circuit board 22A is provided so as to overlap one end of the first circuit board 21 in the first direction D1.

[0083] Figure 12 is a top-down perspective view of the first circuit board 21A. As shown in Figure 12, the first circuit board 21A is provided with a first connector terminal connection hole 38 (first connector connection portion) to which the first press-fit terminal 81 is connected, instead of the connector terminal connection hole 35. The first connector terminal connection hole 38 is provided at one end of the first circuit board 21A in the first direction D1. The first connector terminal connection hole 38 is located in the center of the first circuit board 21A in the second direction D2.

[0084] The first circuit board 21A is provided with a connector terminal through-hole 39 through which the second press-fit terminal 82 is inserted. The connector terminal through-hole 39 is provided at one end of the first circuit board 21A in the first direction D1. The connector terminal through-hole 39 is located on both sides of the first connector terminal connection hole 38 in the second direction D2. In a plan view, the size of the connector terminal through-hole 39 is larger than the size of the second press-fit terminal 82. Therefore, when the second press-fit terminal 82 is inserted into the connector terminal through-hole 39, contact between the second press-fit terminal 82 and the connector terminal through-hole 39 is prevented. Alternatively, instead of the connector terminal through-hole 39, a notch may be formed in the first circuit board 21A to prevent interference between the first circuit board 21A and the second press-fit terminal 82.

[0085] Figure 13 is a top-down perspective view of the second circuit board 22A. As shown in Figure 13, the second circuit board 22A is provided with a second connector terminal connection hole 45 (second connector connection portion) to which the second press-fit terminal 82 is connected. The second connector terminal connection hole 45 is provided at one end of the second circuit board 22A in the first direction D1.

[0086] Figure 14 is a perspective view of the retaining member 24A from above. As shown in Figure 14, in this embodiment, the retaining member 24A further has a support portion 58. The support portion 58 is frame-shaped with an inner space. The support portion 58 is connected to one end of the base portion 51 in a first direction D1. The support portion 58 is in contact with the first circuit board 21A and the second circuit board 22A. In a plan view, the support portion 58 is provided to surround the first connector terminal connection hole 38 of the first circuit board 21A. The support portion 58 supports the area around the first connector terminal connection hole 38 on the first circuit board 21A. The tip of the first press-fit terminal 81 connected to the first connector terminal connection hole 38 is housed in the inner space of the support portion 58. This prevents the first press-fit terminal 81 from coming into contact with the retaining member 24A.

[0087] In the manufacturing method of the rotating electric machine 100A according to this embodiment, the connector assembly 27A is connected to the first circuit board 21A and the second circuit board 22A during the connector mounting process. The other processes (board unit assembly process, board unit fixing process, and cover mounting process) are the same as in Embodiment 1, so they are omitted from this description.

[0088] In the connector mounting process, first, the intermediate structure of the rotating electric machine 100A, after the board unit fixing process has been completed, is inverted. The connector assembly 27A is positioned opposite the second surface 21b of the first circuit board 21A. The connector positioning projection 75 is inserted through the connector positioning through hole 37 of the first circuit board 21A. At this time, the second press-fit terminal 82 is inserted through the connector terminal through hole 39 of the first circuit board 21A. A receiving jig 200 is placed on the fourth surface 22b of the second circuit board 22A. A load is applied to the connector assembly 27A toward the first circuit board 21A. This press-fits the first press-fit terminal 81 into the first connector terminal connection hole 38 of the first circuit board 21A and the second press-fit terminal 82 into the second connector terminal connection hole 45 of the second circuit board 22A.

[0089] Here, when the first press-fit terminal 81 is press-fitted into the first connector terminal connection hole 38, a pressing force is applied to the first circuit board 21A. Similarly, when the second press-fit terminal 82 is press-fitted into the second connector terminal connection hole 45, a pressing force is applied to the second circuit board 22A. In this embodiment, the support portion 58 is provided between the first circuit board 21A and the second circuit board 22A, surrounding the first connector terminal connection hole 38. Therefore, the area around the first connector terminal connection hole 38 on the first circuit board 21A is supported by the support portion 58. In addition, a receiving jig 200 is provided on the fourth surface 22b of the second circuit board 22A. This allows the pressing force applied to the first circuit board 21A to be received by the receiving jig 200 via the support portion 58. Similarly, the pressing force applied to the second circuit board 22A can be received by the receiving jig 200. Therefore, distortion of the first circuit board 21A can be suppressed, and connection failure of the first press-fit terminal 81 due to insufficient insertion of the first press-fit terminal 81 into the first connector terminal connection hole 38 can be prevented. In addition, distortion of the second circuit board 22A can be suppressed, and connection failure of the second press-fit terminal 82 due to insufficient insertion of the second press-fit terminal 82 into the second connector terminal connection hole 45 can be prevented. Subsequently, the connector assembly 27A is screw-fixed to the heat sink 25 using the second fastening member 77.

[0090] As described above, in the rotating electric machine 100A according to this embodiment, the connector assembly 27A further has a second press-fit terminal 82 connected to the second circuit board 22A. The second circuit board 22A has a second connector terminal connection hole 45 provided at one end in the first direction D1 of the second circuit board 22A, to which the second press-fit terminal 82 is connected. The holding member 24A is provided so as to surround the first connector terminal connection hole 38 when viewed from the axial direction, and further has a support portion 58 that abuts against the first circuit board 21A and the second circuit board 22A. This configuration allows signals from external sensors to be directly input from the connector assembly 27A to the second circuit board 22A. This eliminates the need to provide terminals on the board-to-board connector 23 for transmitting the signals from the first circuit board 21A to the second circuit board 22A, allowing the board-to-board connector 23 to be miniaturized. Therefore, the mounting area for electronic components on the first circuit board 21A and the second circuit board 22A can be increased. Furthermore, the support portion 58 supports the area around the first connector terminal connection hole 38 on the first circuit board 21A. When the first press-fit terminal 81 and the second press-fit terminal 82 are connected to the first connector terminal connection hole 38 and the second connector terminal connection hole 45, respectively, a pressing force is applied to the first circuit board 21A and the second circuit board 22A. Since the support portion 58 can receive this pressing force, distortion of the first circuit board 21A and the second circuit board 22A can be suppressed. In addition, poor connection of the first press-fit terminal 81 due to insufficient insertion into the first connector terminal connection hole 38, and poor connection of the second press-fit terminal 82 due to insufficient insertion into the second connector terminal connection hole 45 can be prevented.

[0091] A modified example of Embodiment 2. Figure 15 is a perspective view from below of a modified example of the second embodiment of the holding member 24A. In this modified example, the retaining member 24A further has a guide portion 84. The guide portion 84 has a guide through hole 84a that penetrates the guide portion 84 in the axial direction. The multiple guide through holes 84a are positioned to overlap with the multiple second connector terminal connection holes 45 in a plan view. The lower end (one end) of the guide through hole 84a is formed in a tapered shape that gradually widens in diameter as it goes downward (to one side). In the connector mounting process, the second press-fit terminal 82 is inserted into the guide through-hole 84a from below (one side). Because the lower end of the guide through-hole 84a is tapered, the second press-fit terminal 82 can be smoothly inserted into the guide through-hole 84a. The second press-fit terminal 82 is guided by the guide through-hole 84a toward the second connector terminal connection hole 45 and press-fitted into the second connector terminal connection hole 45. Furthermore, in a plan view, the size of the guide through-hole 84a is larger than the size of the second press-fit terminal 82. Therefore, when the second press-fit terminal 82 is inserted through the guide through-hole 84a, contact between the second press-fit terminal 82 and the guide through-hole 84a is prevented.

[0092] As described above, the retaining member 24A according to this modified example has a guide portion 84 having a guide through hole 84a through which the second press-fit terminal 82 is inserted from one side. One end of the guide through hole 84a is tapered. With this configuration, the guide portion 84 guides the second press-fit terminal 82 toward the second connector terminal connection hole 45, thereby preventing misalignment between the position of the second press-fit terminal 82 and the position of the second connector terminal connection hole 45. This ensures that the second press-fit terminal 82 is reliably inserted into the second connector terminal connection hole 45. Furthermore, it prevents buckling of the second press-fit terminal 82, damage to the second connector terminal connection hole 45, etc., caused by misalignment between the position of the second press-fit terminal 82 and the second connector terminal connection hole 45. In addition, since one end of the guide through-hole 84a is tapered, the second press-fit terminal 82 can be smoothly inserted into the guide through-hole 84a. Therefore, the reliability of the connection portion of the second press-fit terminal 82 can be improved without increasing the number of parts.

[0093] Embodiment 3. Next, the rotating electric machine 100B according to Embodiment 3 will be described. The rotating electric machine 100B according to this embodiment has the same basic configuration as Embodiment 1, so the differences will be the main points to be explained.

[0094] Embodiment 3 differs from Embodiment 1 in that the control unit 2 further comprises a third circuit board 91, a second retaining member 92, and a second inter-board connector 93. The board unit 20A is composed of a first circuit board 21, a second circuit board 22, an inter-board connector 23, a retaining member 24, a third circuit board 91, a second retaining member 92, and a second inter-board connector 93.

[0095] The third circuit board 91 is positioned above the second circuit board 22. The second inter-board connector 93 is positioned axially between the second circuit board 22 and the third circuit board 91. The second inter-board connector 93 electrically connects the second circuit board 22 and the third circuit board 91.

[0096] In this embodiment, the second positioning projection 56 of the retaining member 24 penetrates the second circuit board 22 and the third circuit board 91 in the axial direction. The second positioning projection 56 positions the second circuit board 22 and the third circuit board 91 relative to the retaining member 24.

[0097] The second retaining member 92 is positioned between the second circuit board 22 and the third circuit board 91 in the axial direction. The second retaining member 92 holds the second circuit board 22 and the third circuit board 91. Similar to the retaining member 24 according to Embodiment 1, the second retaining member 92 has a third locking portion (not shown) that locks the second circuit board 22 from the third surface 22a of the second circuit board 22, and a fourth locking portion (not shown) that locks the third circuit board 91 from the upper surface of the third circuit board 91.

[0098] The second holding member 92 includes a second spacer 92a and a second load transmission portion 92b. The second spacer 92a is cylindrical in shape and extends in the axial direction. Multiple second spacers 92a are arranged in a position that overlaps with multiple spacers 54 in a plan view. One end of the second spacer 92a in the axial direction abuts against the second circuit board 22, and the other end of the second spacer 92a in the axial direction abuts against the third circuit board 91. The second spacers 92a ensure a gap between the second circuit board 22 and the third circuit board 91. The second spacer 92a has a fourth fastening through-hole that penetrates the second spacer 92a in the axial direction. A fastening member 26 is inserted through the fourth fastening through-hole. The second load transmission unit 92b is positioned to overlap with the thermal grease 29 in a plan view. The second load transmission unit 92b is in contact with the second circuit board 22 and the third circuit board 91. The load applied to the third circuit board 91 during the manufacturing of the rotating electric machine 100 is transmitted to the first circuit board 21 via the second load transmission unit 92b, the second circuit board 22, and the load transmission unit 57. As a result, the first circuit board 21 is pressed toward the heat sink 25, and the thermal grease 29 applied between the heat sink 25 and the electronic components 28 mounted on the first circuit board 21 is spread out.

[0099] In the manufacturing method of the rotating electric machine 100B according to this embodiment, in the substrate unit assembly process, the substrate unit 20A is assembled by holding the first circuit board 21, the second circuit board 22, and the third circuit board 91 with the holding member 24 and the second holding member 92. At this time, the second positioning projection 56 positions the second circuit board 22 and the third circuit board 91 with respect to the holding member 24, so that the substrate unit 20A can be assembled with the same precision as in Embodiment 1. Note that the other processes (board unit assembly process, connector mounting process, and cover mounting process) are the same as in Embodiment 1, so they are omitted from this description.

[0100] As described above, in the rotating electric machine 100B according to this embodiment, the substrate unit 20A further comprises a third circuit board 91 and a second holding member 92 which is disposed between the second circuit board 22 and the third circuit board 91 and holds the second circuit board 22 and the third circuit board 91. With this configuration, even if the number of circuit boards in the control unit 2 increases, the same effects as in Embodiment 1 can be obtained. That is, the board unit 20A is assembled by holding the first circuit board 21, the second circuit board 22, and the third circuit board 91 with the holding member 24 and the second holding member 92. Then, by fixing the board unit 20A to the heat sink 25 with the fastening member 26, the first circuit board 21, the second circuit board 22, and the third circuit board 91 can be assembled to the heat sink 25 all at once and with high precision. Since it is not necessary to assemble the circuit boards 21, 22, and 91 one by one, the manufacturing of the rotating electric machine 100B becomes easier. In addition, since the manufacturing line for the rotating electric machine 100B can be shared with the manufacturing line for a rotating electric machine in which the control unit is composed of a single circuit board, manufacturing costs can be reduced. Furthermore, the same effect can be obtained even when the number of circuit boards in control unit 2 is four or more.

[0101] Furthermore, it is possible to combine the various embodiments, or to modify or omit the embodiments as appropriate.

[0102] The heat sink 25 may be formed integrally with the motor case 14 of the rotating electric machine 100. For example, the fastening member 26 only needs to be able to fix the substrate unit 20 to the heat sink 25, and is not limited to screws. The number and arrangement of the fastening member 26, the first locking portion 52 and second locking portion 53 of the holding member 24, the spacer 54, the first positioning projection 55 and the second positioning projection 56, and the press-fit terminal 74 of the connector assembly 27 may be appropriately changed according to the specifications of the rotating electric machine 100. [Explanation of symbols]

[0103] 1…Motor, 2…Control unit, 11…Rotating shaft, 12…Rotor, 13…Stator, 15…Armature winding, 16…Annular wiring section, 17…Wiring terminals, 20, 20A…Circuit board unit, 21, 21A…First circuit board, 22, 22A…Second circuit board, 23…Inter-board connector, 24, 24A…Holding member, 25…Heat sink, 26…Fastening member, 27, 27A…Connector assembly, 28…Electronic component, 29…Thermal grease, 32…Motor terminal connection hole (Motor connection section), 35…Connector terminal connection hole (First connector connection section), 38…First connector terminal connection hole (First connector 39... Connector terminal through hole, 43... Notch, 45... Second connector terminal connection hole (second connector connection part), 51... Base, 52... First locking part, 53... Second locking part, 54... Spacer, 55... First positioning projection, 56... Second positioning projection, 57... Load transmission part, 58... Support part, 74... Press-fit terminal (first press-fit terminal), 75... Connector positioning projection, 81... First press-fit terminal, 82... Second press-fit terminal, 84... Guide part, 84a... Guide through hole, 91... Third circuit board, 92... Second retaining member, 100, 100A, 100B... Rotating electric machine

Claims

1. A motor having a rotating shaft, A control unit that controls the motor, Equipped with, The control unit is A substrate unit having a first circuit board and a second circuit board, and a holding member disposed between the first circuit board and the second circuit board and holding the first circuit board and the second circuit board, A heat sink is disposed between the motor and the substrate unit so as to face the first circuit board in the axial direction of the rotating shaft, The substrate unit is further comprising a fastening member for fixing it to the heat sink, The aforementioned retaining member is The base and, A first locking portion is connected to the base and locks the first circuit board from a second surface of the first circuit board that is opposite to the first surface facing the base, A second locking portion is connected to the base and locks the second circuit board from the fourth surface of the second circuit board opposite to the third surface facing the base, It has, The fastening member penetrates the substrate unit in the axial direction and is fastened to the heat sink. Rotating electric machine.

2. The holding member further includes a spacer connected to the base, extending in the axial direction, and in contact with the first circuit board and the second circuit board. The fastening member is inserted through the spacer. The rotating electric machine according to claim 1.

3. The aforementioned retaining member is A first positioning projection is connected to the base, penetrates the first circuit board in the axial direction, and is inserted into the heat sink, A second positioning projection is connected to the base and penetrates the second circuit board in the axial direction, It has, The rotating electric machine according to claim 1 or 2.

4. Electronic components are mounted on the first circuit board, A thermal grease is provided between the heat sink and the electronic component. The holding member is positioned so as to overlap with the heat dissipation grease when viewed from the axial direction, and further includes a load transmission portion that contacts the first circuit board and the second circuit board. The rotating electric machine according to claim 1 or 2.

5. The motor comprises a rotor fixed to the rotating shaft, a stator positioned on the outer circumference of the rotor, an armature winding wound around the stator, and wiring terminals electrically connected to the armature winding and connected to the first circuit board. The first circuit board has a motor connection portion to which the wiring terminals are connected, The second circuit board has a notch that exposes the motor connection portion when the board unit is viewed from the second circuit board side along the axial direction. The rotating electric machine according to claim 1 or 2.

6. The rotating electric machine according to claim 2, wherein, when viewed from the axial direction, the outer shape of the head of the fastening member is substantially the same as the outer shape of the spacer.

7. The control unit further comprises a connector assembly having a first press-fit terminal connected to the first circuit board, The first circuit board has a first connector connection portion provided at one end of the first circuit board in a first direction perpendicular to the axial direction, to which the first press-fit terminal is connected. When the substrate unit is viewed from the second circuit board side along the axial direction, the length of the second circuit board in the first direction is shorter than the length of the first circuit board in the first direction, such that one end of the first circuit board in the first direction is exposed from the second circuit board. The rotating electric machine according to claim 1 or 2.

8. The connector assembly further includes a second press-fit terminal connected to the second circuit board, The second circuit board has a second connector connection portion provided at one end in the first direction of the second circuit board, to which the second press-fit terminal is connected. The holding member is provided so as to surround the first connector connection portion when viewed from the axial direction, and further includes a support portion that contacts the first circuit board and the second circuit board. The rotating electric machine according to claim 7.

9. The retaining member has a guide portion having a guide through hole through which the second press-fit terminal is inserted from one side. The end of the guide through-hole on one side is tapered. The rotating electric machine according to claim 8.

10. The rotating electric machine according to claim 7, wherein the connector assembly has a connector positioning projection that is inserted into the first circuit board.

11. The rotating electric machine according to claim 10, wherein the tip of the connector positioning projection is located on the first circuit board side than the tip of the first press-fit terminal.

12. The rotating electric machine according to claim 1 or 2, wherein the substrate unit further comprises a third circuit board and a second holding member disposed between the second circuit board and the third circuit board and holding the second circuit board and the third circuit board.

13. The rotating electric machine according to claim 1 or 2, wherein the substrate unit further comprises an inter-substrate connector for electrically connecting the first circuit board and the second circuit board.

14. A circuit board unit assembly step of assembling a circuit board unit by holding a first circuit board and a second circuit board with a holding member having a base and a first locking portion and a second locking portion connected to the base, A substrate unit fixing step is performed by passing a fastening member through the substrate unit in the axial direction of the motor's rotating shaft and fastening the fastening member to the heat sink, thereby fixing the substrate unit to the heat sink. Equipped with, A method for manufacturing a rotating electric machine, comprising the following steps in the substrate unit assembly process: the first locking portion locks the first circuit board from a second surface of the first circuit board opposite to the first surface facing the base portion; and the second locking portion locks the second circuit board from a fourth surface of the second circuit board opposite to the third surface facing the base portion.

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