Motor device

Abstract

To provide a motor device in which the accuracy of positioning a substrate to a housing can be increased without reducing the assembly performance.SOLUTION: A sensor substrate 50 has a first long side part 52a and a first short side part 53a crossing with each other. A bracket 40 includes: two positioning protrusions of a first positioning protrusion 45a and a second positioning protrusion 45b in contact with the first long side part 52a; and a third positioning protrusion 45c in contact with the first short side part 53a. The above structure can increase the accuracy of positioning the sensor substrate 50 to the bracket 40 without reducing the assembly performance.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] The present invention relates to a motor device comprising a stator, a rotor that rotates relative to the stator, and a substrate. [Background Art]

[0002] For example, Patent Document 1 describes a motor unit including a stator core, a rotor that rotates relative to the stator core, and an inverter substrate. The inverter substrate is provided with a positioning hole, and a housing that accommodates the inverter substrate is provided with a pin portion. The inverter substrate is positioned at a prescribed position of the housing by inserting the pin portion into the positioning hole, and is fixed to the housing by a screw member. [Prior Art Literature] [Patent Literature]

[0003] [Patent Document 1] Japanese Unexamined Patent Publication No. 2020-058109 [Summary of the Invention] [Problem to be Solved by the Invention]

[0004] However, in the motor unit described in Patent Document 1, it has been difficult to simultaneously achieve both improvement in positional accuracy of the inverter substrate with respect to the housing and improvement in assemblability of the motor unit.

[0005] That is, in order to improve the positional accuracy of the inverter substrate with respect to the housing, it is necessary to reduce the play of the pin portion relative to the positioning hole. In this case, however, it becomes difficult to insert the pin portion into the positioning hole, which causes a problem that the assemblability of the motor unit decreases.

[0006] In contrast, improving the ease of assembly of the motor unit requires increasing the play of the pin portion relative to the positioning hole, but this leads to the problem of reduced positional accuracy of the inverter board relative to the housing.

[0007] The object of the present invention is to provide a motor device that can improve the positional accuracy of the substrate relative to the housing without reducing ease of assembly. [Means for solving the problem]

[0008] In one embodiment of a motor device, the motor device comprises a housing, a stator housed in the housing, a rotor that rotates relative to the stator, and a substrate housed in the housing and formed in the shape of a polygonal flat plate, wherein the substrate has a first side and a second side extending in directions intersecting each other, and the housing comprises two first contact protrusions that abut against the first side and one second contact protrusion that abuts against the second side. The first abutment projection is provided at a position adjacent to the longitudinal center of the first side, and the second abutment projection is positioned closer to the first side than to the longitudinal center of the second side, and reinforcing ribs are provided at the base ends of the first and second abutment projections, respectively. ru. [Effects of the Invention]

[0009] According to the present invention, the positional accuracy of the substrate relative to the housing can be improved without reducing the ease of assembly. [Brief explanation of the drawing]

[0010] [Figure 1] This is a perspective view of the motor unit as seen from the bracket side. [Figure 2] This is a perspective view of the motor unit from the case side. [Figure 3] This is a cross-sectional view showing the internal structure of a motor device. [Figure 4] This is a perspective view looking inside the case. [Figure 5] This is a perspective view looking inside the bracket. [Figure 6] This is a plan view of the bracket as seen from the case side. [Figure 7]This is a perspective view of the sensor board that will be mounted on the bracket. [Figure 8] This is a perspective view illustrating the assembly procedure for the bracket. [Figure 9] This is a plan view illustrating the procedure for positioning the sensor board onto the bracket. [Figure 10] This is a perspective view illustrating the procedure for fixing the sensor board to the bracket. [Modes for carrying out the invention]

[0011] Hereinafter, one embodiment of the present invention will be described in detail with reference to the drawings.

[0012] Figure 1 is a perspective view of the motor unit as seen from the bracket side, Figure 2 is a perspective view of the motor unit as seen from the case side, Figure 3 is a cross-sectional view showing the internal structure of the motor unit, Figure 4 is a perspective view looking inside the case, Figure 5 is a perspective view looking inside the bracket, Figure 6 is a plan view of the bracket as seen from the case side, and Figure 7 is a perspective view of the sensor board mounted on the bracket.

[0013] <Motor device> The motor device 10 shown in Figures 1 to 3 is used, for example, as a drive source for an electric brake system mounted on a vehicle such as an automobile. The motor device 10 is a brushless motor and is equipped with a metal case 20. The case 20 is formed into a bottomed cylindrical shape by deep drawing or the like from a metal plate. The case 20 has a cylindrical portion 21, and a bottom wall portion 22 is provided on one axial side of the cylindrical portion 21 (the lower side in Figure 3). An opening 23 is provided on the other axial side of the cylindrical portion 21 (the upper side in Figure 3).

[0014] As shown in Fig. 4, a flange portion 24 projecting radially outward is provided on the opening 23 side of the cylindrical portion 21, and the flange portion 24 is attached to one axial side (the lower side in Fig. 3) of a resin bracket 40 by a total of three first male screw members S1. The flange portion 24 is provided with a first insertion hole H1 through which the first male screw member S1 is inserted, and a second insertion hole H2 through which a fixing bolt (not shown) for fixing the motor device 10 to a driven object (such as an electric brake device) is inserted.

[0015] As described above, the opening 23 of the metal case 20 is closed by the resin bracket 40. The tip end side of the first male screw member S1 is tightened by a Phillips (+) screwdriver (not shown).

[0016] Here, the case 20 and the bracket 40 each correspond to the housing in the present invention.

[0017] <Stator> As shown in Fig. 3, a stator (fixed member) 25 is housed inside the case 20. Specifically, the stator 25 is fixed to the radially inner side of the cylindrical portion 21 by press fitting or the like. The stator 25 includes a stator core 26 formed in a substantially cylindrical shape, and the stator core 26 is formed by laminating a plurality of thin steel plates. The stator core 26 includes a core body 26a formed in a substantially cylindrical shape, and a plurality of teeth 26b projecting radially inward from the core body 26a.

[0018] A resin insulator 27 is attached to each of the plurality of teeth 26b, and a coil 28 consisting of U-phase, V-phase, and W-phase is wound around the outer side of the insulator 27 in a predetermined winding method and a predetermined number of turns. That is, three-phase coils 28 are respectively wound around the plurality of teeth 26b via the insulator 27 functioning as an insulating member. The three-phase coils 28 are alternately arranged in the circumferential direction of the stator 25 in the order of U-phase, V-phase, W-phase, and so on.

[0019] As shown in Figures 3 and 4, an annular busbar unit 29 is mounted on the other axial side of the stator 25 (upper side in Figure 3). The busbar unit 29 comprises a plurality of conductive members 30 corresponding to the U, V, and W phases, and these conductive members 30 are held by an annular retaining member 29a. The retaining member 29a is made of an insulator such as plastic and prevents short circuits between the conductive members 30.

[0020] One end of each conductive member 30 is electrically connected to the end of a three-phase coil 28. On the other hand, one end of a power terminal PT (see Figures 5 and 6) provided on the bracket 40 is electrically connected to the other end of each conductive member 30.

[0021] Here, three power terminals PT are provided, corresponding to the U, V, and W phases, and the other ends of these power terminals PT are exposed inside the connector connection section CN to which the vehicle-side connector member (not shown) is connected (see Figures 5 and 6).

[0022] <Rotor> As shown in Figure 3, the motor device 10 includes a rotor 31 that rotates relative to the stator 25. The rotor 31 has a rotating shaft 32 and a rotor body 33. The rotating shaft 32 is formed into a stepped rod shape by machining a round steel rod. The rotor body 33 includes a rotor core 34 made of multiple thin steel plates laminated together, and a cylindrical magnet 35 mounted radially outside the rotor core 34.

[0023] Furthermore, the radially outer side of the magnet 35 is covered by a cylindrical magnet cover 36 made of stainless steel or the like. The magnet cover 36 is attached to the radially outer side of the magnet 35 by crimping the other axial side (upper side in Figure 3) of the magnet cover 36 radially inward. In order to prevent the crimping force from being applied to the magnet 35, a magnet protection member 37 is provided on the other axial side of the magnet cover 36. This ensures that the air gap AG between the rotor body 33 and the stator 25 is maintained with high precision.

[0024] Furthermore, one axial side of the rotating shaft 32 (the lower side in Figure 3) is fixed to the rotation center of the rotor core 34 by press-fitting or the like. As a result, the rotating shaft 32 rotates in conjunction with the rotation of the rotor core 34.

[0025] An annular sensor magnet SM is provided approximately in the axial direction of the rotating shaft 32. The sensor magnet SM is fixed to the rotating shaft 32 via a holder member 38. The sensor magnet SM is used to detect the rotational state of the rotating shaft 32 and rotates in accordance with the rotation of the rotating shaft 32.

[0026] Specifically, the sensor magnet SM is provided with north and south poles facing each other in its axial direction, and the direction of the magnetic flux of the sensor magnet SM is in the axial direction of the sensor magnet SM. As a result, the magnetic flux of the sensor magnet SM passes through a total of three Hall elements 51 (see Figure 7) arranged in the axial direction of the sensor magnet SM. In the circumferential direction of the sensor magnet SM, the direction of the magnetic flux alternates between one axial side and the other axial side, and each Hall element 51 detects this change in the direction of the magnetic flux. As a result, the in-vehicle controller (not shown) detects the rotational state (direction of rotation, rotational speed, etc.) of the rotor 31 (rotating shaft 32).

[0027] Here, the rotating shaft 32 is positioned to pass through a through hole 52 provided in the sensor substrate 50 and cross the bracket 40. One axial side of the rotating shaft 32 (the lower side in Figure 3) is rotatably supported by a first bearing BR1 mounted on the bottom wall 22 of the case 20. In contrast, the other axial side of the rotating shaft 32 (the upper side in Figure 3) is rotatably supported by a second bearing BR2 mounted on the bracket 40. The first and second bearings BR1 and BR2 are both ball bearings (not shown in detail).

[0028] Furthermore, a pinion gear section 32a is integrally provided at the other axial end of the rotating shaft 32. The pinion gear section 32a forms the output section of the motor device 10. Specifically, the pinion gear section 32a is connected to, for example, a feed screw shaft (not shown) that moves the piston of an electric brake device forward and backward, in a manner that allows for power transmission.

[0029] Here, the motor device 10 is not limited to a surface-mounted magnet type (Surface Permanent Magnet) in which the magnet 35 is attached to the surface of the rotor core 34 as described above, but may also be an interior-mounted magnet type (Interior Permanent Magnet) in which the magnet is embedded inside the rotor core.

[0030] <bracket> As shown in Figures 3, 5, and 6, the bracket 40 has the function of fixing the motor device 10 to the object to be driven. The bracket 40 is formed in a roughly disc shape by injection molding of a resin material such as molten plastic. In other words, the bracket 40 is an injection molded product.

[0031] <Insertion tube section> The bracket 40 is equipped with a partition wall portion 41 that is formed in a substantially disc shape. The partition wall portion 41 separates the case 20 side (lower side in Figure 3) from the drive object side (upper side in Figure 3), and an insertion cylinder portion 42 is integrally provided in the center of the partition wall portion 41 through which the other axial side (upper side in Figure 3) of the rotating shaft 32 is inserted.

[0032] Furthermore, a bearing holder 43, formed in a roughly cup shape by press-forming a steel plate, is provided on the radially inner side of the insertion cylinder portion 42. Specifically, the radially outer side of the bearing holder 43 is fixed to the radially inner side of the insertion cylinder portion 42.

[0033] The bearing holder 43 is provided with a through hole 43a through which the rotating shaft 32 is inserted, and the bearing holder 43 holds the second bearing BR2 coaxially with the insertion cylinder portion 42. An annular fixing plate 44 is provided on one axial side of the second bearing BR2 (the lower side in Figure 3) to prevent the second bearing BR2 from falling out of the bearing holder 43.

[0034] Furthermore, a sensor substrate 50 is provided on one axial side of the insertion cylinder portion 42 (the lower side in Figure 3). Specifically, the sensor substrate 50 is fixed to a total of three substrate fixing portions 42a (see Figure 6) by a total of three second male screw members S2 (see Figure 5). The substrate fixing portions 42a are female screw portions and are integrally provided around the insertion cylinder portion 42 and on the case 20 side of the partition wall portion 41.

[0035] <Positioning protrusion> Furthermore, as shown in Figures 5 and 6, the partition wall portion 41 is integrally provided with a first positioning projection 45a, a second positioning projection 45b, and a third positioning projection 45c on the case 20 side (the front side in Figure 6) to position the sensor substrate 50 in the correct position on the bracket 40. The three first, second, and third positioning projections 45a, 45b, and 45c all protrude in the same direction and at the same height.

[0036] Specifically, these first, second, and third positioning protrusions 45a, 45b, and 45c protrude toward the case 20 in the axial direction of the rotation axis 32, and their protrusion height is such that, when the sensor substrate 50 is fixed to the bracket 40 (see Figure 5), they protrude toward the case 20 more than the sensor substrate 50.

[0037] Furthermore, of the three positioning protrusions 45a, 45b, and 45c in total, the first and second positioning protrusions 45a and 45b are in contact with the first long side portion 52a of the sensor substrate 50. Specifically, the first and second positioning protrusions 45a and 45b are in contact with the first long side portion 52a in a direction intersecting the thickness direction of the sensor substrate 50, that is, in a direction intersecting the axial direction of the rotation axis 32. Note that the first and second positioning protrusions 45a and 45b correspond to the first contact protrusion in this invention.

[0038] Here, the first and second positioning protrusions 45a and 45b are provided at positions that are offset from the longitudinal center of the first long side portion 52a to both sides in the longitudinal direction. In other words, the first and second positioning protrusions 45a and 45b are positioned on both sides in the longitudinal direction of the first long side portion 52a so as to abut against both sides of the first long side portion 52a.

[0039] Furthermore, the first and second positioning protrusions 45a and 45b have a circular cross-sectional shape in the direction intersecting the thickness direction of the sensor substrate 50 (the direction intersecting the axial direction of the rotation axis 32). As a result, the first and second positioning protrusions 45a and 45b each contact the first long side portion 52a at a "point". Therefore, simply by abutting the first long side portion 52a of the sensor substrate 50 against both the first and second positioning protrusions 45a and 45b, the sensor substrate 50 is positioned relative to the first and second positioning protrusions 45a and 45b.

[0040] As shown in Figure 6, a total of four reinforcing ribs RB are provided on the base end side (partition wall 41 side) of the first and second positioning protrusions 45a and 45b. This increases the strength of the first and second positioning protrusions 45a and 45b, suppressing breakage of the first and second positioning protrusions 45a and 45b when the sensor substrate 50 abuts against them.

[0041] Furthermore, of the three positioning protrusions 45a, 45b, and 45c in total, one third positioning protrusion 45c is in contact with the first short side portion 53a of the sensor substrate 50. Specifically, the third positioning protrusion 45c is in contact with the first short side portion 53a in a direction intersecting the thickness direction of the sensor substrate 50, that is, in a direction intersecting the axial direction of the rotation axis 32. Note that the third positioning protrusion 45c corresponds to the second contact protrusion in this invention.

[0042] Here, the third positioning projection 45c is positioned closer to the first long side 52a than to the longitudinal center of the first short side 53a. Furthermore, similar to the first and second positioning projections 45a and 45b, the cross-sectional shape of the third positioning projection 45c in the direction intersecting the thickness direction of the sensor substrate 50 (the direction intersecting the axial direction of the rotation axis 32) is circular.

[0043] As a result, the third positioning projection 45c contacts the first short side portion 53a at a "point". Therefore, simply by abutting the first short side portion 53a of the sensor substrate 50 against the third positioning projection 45c, the sensor substrate 50 is positioned relative to the third positioning projection 45c.

[0044] As shown in Figure 6, a total of four reinforcing ribs RB are also provided on the base end side (partition wall 41 side) of the third positioning projection 45c. This increases the strength of the third positioning projection 45c, preventing it from breaking when the sensor substrate 50 strikes it.

[0045] In this way, by abutting the first long side portion 52a and the first short side portion 53a, which are inclined at a predetermined angle (90 degrees) relative to each other, against a total of three first, second, and third positioning protrusions 45a, 45b, and 45c (3 points), it is possible to accurately position the sensor substrate 50 in a direction intersecting the axial direction of the rotation axis 32 and in the rotational direction of the rotation axis 32.

[0046] This allows the through-hole 52 in the sensor substrate 50 and the rotation center of the rotation axis 32 (see Figure 3) to be precisely aligned with each other, and consequently, the Hall element 51 mounted on the sensor substrate 50 and the sensor magnet SM (see Figure 3) are precisely positioned opposite each other with respect to the axial direction of the rotation axis 32. Therefore, the sensing accuracy of the Hall element 51 can be improved, and variations in sensing accuracy from product to product can be effectively suppressed.

[0047] Here, with the first and second positioning protrusions 45a and 45b in contact with the first long side portion 52a, and the third positioning protrusion 45c in contact with the first short side portion 53a, that is, with the sensor substrate 50 abutting against all three first, second, and third positioning protrusions 45a, 45b, and 45c, the sensor substrate 50 is screwed to the bracket 40 by the second male screw member S2. The procedure for fixing the sensor substrate 50 to the bracket 40 by the second male screw member S2 will be described in detail later.

[0048] <Sensor board> As shown in Figure 3, the sensor substrate 50 is positioned between the second bearing BR2 and the sensor magnet SM on the case 20 side of the bracket 40 (the lower side in Figure 3). In other words, the sensor substrate 50 is housed inside the bracket 40 and case 20. The sensor substrate 50 corresponds to the substrate in this invention.

[0049] As shown in Figure 7, the sensor substrate 50 is formed in the shape of a roughly rectangular (polygonal) flat plate, and a total of three Hall elements 51 are mounted on the mounting surface SF of the sensor substrate 50 on the case 20 side. Specifically, these Hall elements 51 are arranged around a through hole 52 located approximately in the center of the sensor substrate 50, and face the sensor magnet SM in the axial direction of the rotation axis 32.

[0050] The three Hall elements 51 detect the rotational state (direction of rotation, rotational speed, etc.) of the rotor 31 (rotating shaft 32), and correspond to the rotation sensor in this invention.

[0051] The sensor substrate 50 comprises a pair of first and second long sides 52a and 52b arranged opposite each other, and a pair of first and second short sides 53a and 53b arranged opposite each other. The first and second long sides 52a and 52b each correspond to the long sides in the present invention, with the first long side 52a corresponding to the first side in the present invention. The first and second short sides 53a and 53b each correspond to the short sides in the present invention, with the first short side 53a corresponding to the second side in the present invention.

[0052] Furthermore, the first long side 52a and the first short side 53a extend in directions that intersect each other, and the relative angle between the first long side 52a and the first short side 53a is 90 degrees (right angle).

[0053] Furthermore, a first chamfered portion C1 is provided between the first long side portion 52a and the first short side portion 53a, a second chamfered portion C2 is provided between the first short side portion 53a and the second long side portion 52b, a third chamfered portion C3 is provided between the second long side portion 52b and the second short side portion 53b, and a fourth chamfered portion C4 is provided between the second short side portion 53b and the first long side portion 52a.

[0054] Furthermore, the sensor substrate 50 is provided with a total of three screw insertion holes 54 through which the second male screw member S2 (see Figure 5) is inserted, and a total of five through holes TH to which one end of each of the five sensor terminals ST (see Figure 6) is electrically connected. The other ends of the five sensor terminals ST are exposed on the inside of the connector connection portion CN to which the vehicle-side connector member (not shown) is connected (see Figures 5 and 6).

[0055] Specifically, one of the three screw insertion holes 54 is located near the first short side portion 53a and in the center of the direction of extension of the first short side portion 53a. The other two of the three screw insertion holes 54 are located near the third chamfer portion C3 and near the fourth chamfer portion C4, respectively. Furthermore, the five through-holes TH are located near the second short side portion 53b and are arranged at equal intervals in the direction of extension of the second short side portion 53b.

[0056] <First terminal hole and second terminal hole> As shown in Figure 6, the partition wall 41 is provided with a first terminal hole 41a, where one end of a total of three power terminals PT is placed, and a second terminal hole 41b, where one end of a total of five sensor terminals ST is placed. These first terminal holes 41a and second terminal holes 41b are located near the connector connection portion CN and are positioned close to each other. This allows each terminal PT and ST to be shortened, thereby preventing the bracket 40 from becoming overly complex. Each terminal PT and ST is provided on the bracket 40 by insert molding.

[0057] Furthermore, as shown in Figure 1, the first terminal hole 41a and the second terminal hole 41b are fitted with a first cap CP1 and a second cap CP2, respectively. Specifically, the first and second caps CP1 and CP2 are both made of a resin material such as plastic and are fixed to the first and second terminal holes 41a and 41b by snap-fit ​​or the like. These first and second caps CP1 and CP2 also separate the case 20 side from the driven object side, similar to the partition wall 41.

[0058] <Cylindrical wall section> As shown in Figures 1, 3, 5, and 6, a cylindrical wall portion 46 with a larger diameter than the insertion cylinder portion 42 is provided on the radially outer side of the insertion cylinder portion 42. Specifically, the cylindrical wall portion 46 is integrally provided on the radially outer side of the partition wall portion 41.

[0059] The cylindrical wall portion 46 is arranged coaxially with respect to the insertion cylinder portion 42 and extends in the axial direction of the rotation shaft 32. On one axial side of the cylindrical wall portion 46 (lower side in Figure 3), there is a case side surface 46a facing the flange portion 24 of the case 20. On the other axial side of the cylindrical wall portion 46 (upper side in Figure 3), there is a drive object side surface 46b facing the drive object.

[0060] The cylindrical wall portion 46 is integrally provided with a total of three drive target fixing portions 47. These drive target fixing portions 47 are equipped with cylindrical metal collars CL. This allows the motor device 10 to be securely fixed to the drive target without damaging the resin drive target fixing portions 47.

[0061] The drive target fixing portion 47 is arranged at predetermined intervals in the circumferential direction of the cylindrical wall portion 46, and as shown in Figure 6, when the bracket 40 is viewed from one axial side (case 20 side), it protrudes radially outward from the cylindrical wall portion 46. In addition, fixing bolts for fixing the motor device 10 to the drive target are inserted through the collar CL held by the drive target fixing portion 47.

[0062] Furthermore, a connector connection portion CN is integrally provided on the radially outer side of the cylindrical wall portion 46. The connector connection portion CN is formed in a substantially rectangular parallelepiped shape, and a connector member from the vehicle side can be connected from one axial side of the cylindrical wall portion 46 (the lower side in Figure 3).

[0063] Furthermore, as shown in Figures 5 and 6, a total of three case fixing parts 48 are integrally provided on the cylindrical wall portion 46. These case fixing parts 48 are the parts to which the flange portion 24 of the case 20 is fixed, and each holds a cylindrical female thread member IT made of steel. Specifically, the female thread members IT are provided on the bracket 40 by insert molding during injection molding of the bracket 40, similar to the respective terminals PT and ST. Then, first male thread members S1 for fixing the case 20 to the bracket 40 are screwed to each of these female thread members IT.

[0064] Here, the three case fixing parts 48 are arranged at predetermined intervals in the circumferential direction of the cylindrical wall portion 46, and the case fixing parts 48 are provided between adjacent drive object fixing parts 47. Furthermore, as shown in Figure 6, each case fixing part 48 protrudes radially outward from the cylindrical wall portion 46 when the bracket 40 is viewed from one axial side (case 20 side).

[0065] Furthermore, a fitting cylinder portion 49 is integrally provided on one axial side of the bracket 40, between the insertion cylinder portion 42 and the cylindrical wall portion 46 in the radial direction of the bracket 40. The fitting cylinder portion 49 is the part that fits into the opening 23 of the case 20, and an annular seal SL made of an elastic material such as rubber is attached to its radially outer side. The annular seal SL seals the space between the bracket 40 and the case 20.

[0066] <Bracket assembly instructions> Next, the assembly procedure for the motor device 10 formed as described above, and in particular the procedure for assembling the sensor board 50 to the bracket 40, will be explained in detail with reference to the drawings.

[0067] Figure 8 is a perspective view illustrating the assembly procedure for the bracket, Figure 9 is a plan view illustrating the positioning procedure for the sensor board onto the bracket, and Figure 10 is a perspective view illustrating the procedure for fixing the sensor board onto the bracket.

[0068] First, prepare the bracket 40 and sensor substrate 50, which have been manufactured in advance using a separate manufacturing process. Also, prepare a total of three second male screw members S2.

[0069] Next, as shown by arrow M1 in Figure 8, the sensor board 50 is positioned facing the bracket 40. At this time, the mounting surface SF of the sensor board 50 should face the case 20 side (upper side in Figure 8). In other words, in the assembled state of the motor device 10 (see Figure 3), each Hall element 51 should face the sensor magnet SM.

[0070] Furthermore, in the axial direction of the rotating shaft 32 (see Figure 3), the second bearing BR2 and the through hole 52 are positioned opposite each other, while a total of three substrate fixing parts 42a and a total of three screw insertion holes 54 are positioned opposite each other. Then, the sensor substrate 50 is placed on top of the substrate fixing parts 42a. As a result, one end of a total of five sensor terminals ST is inserted into a total of five through holes TH.

[0071] Subsequently, as shown in Figure 9, the first long side portion 52a of the sensor substrate 50 is brought into contact with the first positioning projection 45a and the second positioning projection 45b, and the first short side portion 53a of the sensor substrate 50 is brought into contact with the third positioning projection 45c. At this time, the first long side portion 52a and the first short side portion 53a are pressed with a pressing force F (see shaded arrow) toward the first and second positioning projections 45a, 45b and the third positioning projection 45c, respectively, in a direction intersecting the axial direction of the rotation axis 32.

[0072] As a result, the sensor substrate 50 comes into contact with a total of three first, second, and third positioning protrusions 45a, 45b, and 45c (3 points). Thus, the sensor substrate 50 is positioned in the correct position on the bracket 40.

[0073] Thus, in this embodiment, the sensor substrate 50 can be positioned in the correct position on the bracket 40 simply by abutting the first long side portion 52a against the first and second positioning protrusions 45a and 45b, and abutting the first short side portion 53a against the third positioning protrusion 45c.

[0074] Therefore, compared to the conventional specification in which holes are drilled in the substrate for positioning and pins are inserted into those holes to fix it in place, the sensor substrate 50 can be positioned relative to the bracket 40 easily and with high precision. Specifically, in the positioning structure using holes and pins, the additional work of drilling holes in the substrate is required. And during that drilling work, there was a risk that the position and size of the holes would vary from product to product. In this embodiment, the "drilling work" is omitted, and in turn, it is possible to reduce variations between products.

[0075] Subsequently, as shown in Figure 10, a substrate holding jig TL equipped with a total of three legs FT is used to press down on the positioned sensor substrate 50 to prevent it from shifting. Here, the legs FT of the substrate holding jig TL press down on a position that avoids elements (Hall elements 51, etc.) and printed wiring (not shown) mounted on the mounting surface SF of the sensor substrate 50.

[0076] Next, as shown by arrow M2 in Figure 10, a total of three second male screw members S2 are inserted into a total of three screw insertion holes 54. Then, with the sensor substrate 50 pressed down by the substrate holding jig TL, the three second male screw members S2 are simultaneously tightened to their respective substrate fixing parts 42a (see Figure 8) with a predetermined tightening torque using a fastening jig (not shown).

[0077] In this way, by simultaneously tightening a total of three second male screw members S2 using the fastening jig, distortion and other issues in the sensor board 50 are suppressed. This also allows for accurate positioning of the sensor board 50 relative to the bracket 40. This completes the assembly of the bracket 40 (mounting of the sensor board 50).

[0078] As described in detail above, according to this embodiment, the sensor substrate 50 has a first long side portion 52a and a first short side portion 53a extending in directions intersecting each other, and the bracket 40 includes two first and second positioning protrusions 45a and 45b that abut against the first long side portion 52a, and one third positioning protrusion 45c that abuts against the first short side portion 53a.

[0079] This makes it possible to improve the positional accuracy of the sensor board 50 relative to the bracket 40 without reducing ease of assembly.

[0080] Specifically, since there is no need to drill holes in the sensor substrate 50 for positioning, there is no need to worry about variations in the position and size of holes from product to product. Furthermore, by simply bringing the first long side portion 52a and the first short side portion 53a into contact with a total of three first, second, and third positioning protrusions 45a, 45b, and 45c (3 points), the sensor substrate 50 can be accurately positioned in the direction intersecting the axial direction of the rotation axis 32 and in the rotational direction of the rotation axis 32.

[0081] Furthermore, the through-hole 52 of the sensor substrate 50 and the rotation center of the rotation axis 32 can be precisely aligned with each other, and consequently, the Hall element 51 mounted on the sensor substrate 50 and the sensor magnet SM can be precisely positioned opposite each other with respect to the axial direction of the rotation axis 32. Therefore, the sensing accuracy of the Hall element 51 can be improved, and variations in sensing accuracy from product to product can be effectively suppressed.

[0082] Furthermore, according to this embodiment, the sensor substrate 50 is formed in the shape of a substantially rectangular (polygonal) flat plate having a pair of first and second long sides 52a and 52b arranged opposite to each other, and a pair of first and second short sides 53a and 53b arranged opposite to each other, and first and second positioning protrusions 45a and 45b are arranged on both sides in the longitudinal direction of the first long side 52a, respectively.

[0083] This effectively suppresses rotational displacement of the sensor substrate 50 around the through hole 52, compared to a configuration where the first and second positioning protrusions 45a and 45b are closer together. This also improves the positioning accuracy of the sensor substrate 50 relative to the bracket 40.

[0084] Furthermore, according to this embodiment, the cross-sectional shapes of the three first, second, and third positioning protrusions 45a, 45b, and 45c are circular in the direction intersecting the thickness direction of the sensor substrate 50.

[0085] As a result, the sensor board 50 can be easily positioned relative to the bracket 40 simply by abutting (contacting) the first long side 52a and the first short side 53a of the sensor board 50 against three points. Furthermore, for example, an assembler of the motor device 10 can easily ascertain that the sensor board 50 has been positioned correctly relative to the bracket 40, thereby improving ease of assembly.

[0086] Furthermore, according to this embodiment, the sensor board 50 is equipped with a total of three Hall elements 51 that detect the rotation state of the rotor 31 (rotating shaft 32). In other words, improving the positioning accuracy of the sensor board 50 is an important issue. This embodiment solves this problem and makes it possible to effectively suppress variations in the performance (characteristics) of the motor device 10 from product to product.

[0087] Furthermore, according to this embodiment, variations in the performance (characteristics) of the motor device 10 from product to product can be suppressed, and consequently, the occurrence of defective products can be suppressed. Therefore, it becomes possible to reduce the energy required for manufacturing the motor device 10. This makes it possible to achieve the United Nations Sustainable Development Goals (SDGs), particularly Goal 7 (Ensure access to affordable, reliable, sustainable, and modern energy for all) and Goal 13 (Take urgent action to combat climate change and its impacts).

[0088] The present invention is not limited to the embodiments described above, and can be modified in various ways without departing from its essence. For example, in the embodiments described above, the sensor substrate 50 is shown to be substantially rectangular (quadrilateral), but the present invention is not limited to this, and can be applied to substrates of other shapes as long as they are polygonal flat plates having a pair of sides (first side and second side) that are inclined at a predetermined angle to each other and extend in intersecting directions.

[0089] Furthermore, although the above-described embodiment shows a substrate that is a sensor substrate 50, the present invention is not limited to this and can also be applied to a substrate (control substrate) on which a controller that controls the magnitude of the drive current to the coil 28 wound around the stator 25 is mounted.

[0090] Furthermore, although the above-described embodiment shows the motor device 10 as a drive source for an electric brake system mounted on a vehicle such as an automobile, the present invention is not limited to this and can also be applied to drive sources for other in-vehicle equipment (such as a drive motor for electric power steering).

[0091] Furthermore, the material, shape, dimensions, number, and installation location of each component in the above-described embodiments are arbitrary as long as they can achieve the present invention, and are not limited to the above-described embodiments. [Explanation of Symbols]

[0092] 10: Motor unit, 20: Case (housing), 21: Cylindrical part, 22: Bottom wall part, 23: Opening, 24: Flange part, 25: Stator, 26: Stator core, 26a: Core body, 26b: Teeth, 27: Insulator, 28: Coil, 29: Busbar unit, 29a: Holding member, 30: Conductive member, 31: Rotor, 32: Rotating shaft, 32a: Pinion gear part, 33: Rotor body, 34: Rotor core, 35: Magnet, 36: Magnet cover -, 37: Magnet protection member, 38: Holder member, 40: Bracket (housing), 41: Partition wall, 41a: First terminal hole, 41b: Second terminal hole, 42: Insertion tube, 42a: Substrate fixing part, 43: Bearing holder, 43a: Insertion hole, 44: Annular fixing plate, 45a: First positioning projection (first contact projection), 45b: Second positioning projection (first contact projection), 45c: Third positioning projection (second contact projection), 46: Cylindrical wall, 46a: Case side, 46b : Side of the object to be driven, 47: Fixing part of the object to be driven, 48: Fixing part of the case, 49: Fitting cylinder part, 50: Sensor substrate (substrate), 51: Hall element (rotation sensor), 52: Through hole, 52a: First long side (first side, long side), 52b: Second long side (long side), 53a: First short side (second side, short side), 53b: Second short side (short side), 54: Screw insertion hole, AG: Air gap, BR1: First bearing, BR2: Second bearing, C1: First chamfer, C2: Second chamfer C3: Third chamfer, C4: Fourth chamfer, CL: Collar, CN: Connector connection part, CP1: First cap, CP2: Second cap, F: Pressing force, FT: Leg, H1: First insertion hole, H2: Second insertion hole, IT: Female thread member, PT: Power terminal, RB: Reinforcement rib, S1: First male thread member, S2: Second male thread member, SF: Mounting surface, SL: Annular seal, SM: Sensor magnet, ST: Sensor terminal, TH: Through hole, TL: Board holding jig

Claims

1. Housing and A stator housed in the aforementioned housing, A rotor that rotates relative to the stator, A substrate housed in the aforementioned housing and formed in the shape of a polygonal flat plate, A motor device equipped with, The aforementioned substrate is It has a first side and a second side that extend in directions that intersect each other, The aforementioned housing is Two first contact protrusions that abut the first side portion, A second contact projection that contacts the second side, Equipped with, The first contact projection is provided at a position adjacent to both sides in the longitudinal direction from the longitudinal center of the first side, The second contact projection is positioned closer to the first side than to its longitudinal center relative to the second side. Reinforcing ribs are provided on the base end side of the first and second abutment projections, respectively. Motor device.

2. In the motor device according to claim 1, The aforementioned substrate is A pair of long sides arranged opposite each other, A pair of short sides arranged opposite each other, It has, One of the pair of long sides is the first side. One of the pair of short sides is the second side. Motor device.

3. In a direction intersecting the thickness direction of the substrate, the cross-sectional shapes of the first contact projection and the second contact projection are circular. The motor device according to claim 1.

4. In the motor device according to claim 1, The substrate is equipped with a rotation sensor for detecting the rotation state of the rotor. Motor device.

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