Motor device

Abstract

A controller (3) of a motor device according to the present invention comprises a base plate (61) having a first surface (66) and a second surface (67) that face in opposite directions from each other in the axial direction. The base plate (61) has a main region (61A) and a sub-region (61B) defined by a virtual plane intersecting the first surface (66) and the second surface (67). The motor device comprises a first seal member (101) and a second seal member (102) that extend linearly. The first seal member (101) is interposed between the base plate (61) and a first portion of the motor device that faces the first surface (66) in the axial direction. The second seal member (102) is interposed between the base plate (61) and a second portion of the motor device that faces the second surface (67) in the axial direction. Each of the first seal member (101) and the second seal member (102) has a separating portion extending so as to separate the main region (61A) and the sub-region (61B) from each other.

Description

Motor device

[0001] The present disclosure relates to a motor device.

[0002] For example, Patent Document 1 discloses a motor device including a motor having two winding groups and a controller that individually controls the power supply to the two winding groups. The controller described in Patent Document 1 includes a circuit board that has two regions separated by a boundary line perpendicular to the axial direction of the motor. Each of the two regions is formed with a power circuit that supplies power to the corresponding winding group of the two systems, and a control circuit that controls the power circuit, among other circuits. This allows the motor to continue operating even if an abnormality occurs in one of the two systems by supplying power to the other winding group.

[0003] International Publication No. 2022 / 176166

[0004] In the motor device of Patent Document 1, if a liquid such as water enters the controller, there is a risk that two circuits formed on the board will fail simultaneously.

[0005] A motor device according to one aspect of the present disclosure includes a motor having a main winding group and a secondary winding group, and a controller configured to individually control power supply to the main winding group and the secondary winding group. The motor includes a stator having the main winding group and the secondary winding group, a rotor configured to rotate by power supply to at least one of the main winding group and the secondary winding group, an output shaft that rotates integrally with the rotor, and a housing that accommodates the stator, the rotor, and the output shaft. The controller includes a board having a first surface and a second surface facing oppositely in the axial direction of the output shaft and fixed to the housing, and a cover attached to the housing to cover the board. The board has a main region and a secondary region defined by an imaginary plane intersecting the first surface and the second surface. The main region includes a main power circuit configured to supply power to the main winding group and a main control circuit configured to generate a control signal for controlling the main power circuit. The sub-region has formed therein a sub-power circuit configured to supply power to the sub-winding group and a sub-control circuit configured to generate a control signal for controlling the sub-power circuit. The motor device further includes a first sealant and a second sealant extending linearly. The first sealant is interposed between the substrate and a first portion of the motor device facing the first surface in the axial direction. The second sealant is interposed between the substrate and a second portion of the motor device facing the second surface in the axial direction. The first sealant and the second sealant each have an isolation portion extending to separate the main region and the sub-region from each other.

[0006] 1. A cross-sectional view of the motor device of the first embodiment. 2. A plan view showing the motor device of FIG. 1 with the cover removed. 3. A partial cross-sectional view of the motor device taken along line III-III of FIG. 1. 4. A partial cross-sectional view of the motor device taken along line IV-IV of FIG. 1. 5. A plan view showing the motor device of the second embodiment with the cover removed. 6. A partial cross-sectional view of the motor device taken along line VI-VI of FIG. 5. 7. A partial cross-sectional view of the motor device taken along line VII-VII of FIG. 6. 8. A partial plan view showing the motor device of a modified example with the cover removed. 9. A partial cross-sectional view of the motor device taken along line IX-IX of FIG.

[0007] First Embodiment A first embodiment of a motor device will be described below with reference to the drawings. In this specification, the term "cylindrical" includes, but is not limited to, circular, elliptical, and polygonal with sharp or rounded corners. In addition, in this specification, the term "annular" includes, but is not limited to, circular, elliptical, and polygonal with sharp or rounded corners.

[0008] As shown in Fig. 1, motor device 1 has a motor 2 and a controller 3. Motor 2 is, for example, a three-phase brushless motor. Motor 2 has two winding groups. Controller 3 separately controls the power supply to the two winding groups in motor 2. Motor device 1 is used, for example, in a vehicle steering device, as a source of assist force that assists a driver's steering operation or a steering force that steers steered wheels.

[0009] (Motor) The motor 2 includes a housing 11 , an output shaft 12 , a stator 13 , a rotor 14 , and a bus bar module 15 .

[0010] The housing 11 includes a housing body 21 and a bearing holder 22. The housing body 21 is generally cylindrical with one end closed. Hereinafter, the direction along the axis of the housing body 21 will be referred to as the axial direction of the motor 2 or simply as the axial direction. The housing body 21 and the bearing holder 22 are made of metal.

[0011] The housing main body 21 has a cylindrical first peripheral wall portion 23, an end wall portion 24 that closes one end of the first peripheral wall portion 23, a flange portion 25 that extends radially outward from the open end of the first peripheral wall portion 23, and a second peripheral wall portion 26 that extends axially from the outer peripheral edge of the flange portion 25.

[0012] In this embodiment, the first peripheral wall portion 23 has a circular shape when viewed in the axial direction. The end wall portion 24 has a first insertion hole 27 that penetrates the end wall portion 24 in the axial direction. A first holding portion 28 is provided on the inner surface of the end wall portion 24, protruding from the periphery of the first insertion hole 27 into the first peripheral wall portion 23. A first bearing 29 is held in the first holding portion 28.

[0013] As shown in Figures 1 and 2, the flange portion 25 has a rectangular shape when viewed in the axial direction. The flange portion 25 extends from the open end of the first peripheral wall portion 23 so that one end of the flange portion 25 in the longitudinal direction protrudes significantly. The flange portion 25 has a window portion 31 that penetrates the flange portion 25 in the axial direction. The window portion 31 is, for example, a rectangular hole. As shown in Figure 3, the flange portion 25 has a plurality of support portions 32. The plurality of support portions 32 extend from the flange portion 25 in the axial direction, away from the end wall portion 24. Each support portion 32 has a screw hole 33 that opens at its tip.

[0014] 1 and 2 , the second peripheral wall portion 26 extends from the outer peripheral edge of the flange portion 25 in the axial direction, away from the end wall portion 24. The second peripheral wall portion 26 extends around the entire circumference of the flange portion 25. In other words, when viewed in the axial direction, the second peripheral wall portion 26 has a rectangular shape corresponding to the flange portion 25. The tip of the second peripheral wall portion 26 forms the open end of the housing main body 21.

[0015] The bearing holder 22 has a circular plate shape. The bearing holder 22 is fixed to the housing main body 21 so as to cover the open end of the first peripheral wall portion 23. The bearing holder 22 has a second insertion hole 34 that passes through the bearing holder 22 in the axial direction. A second holding portion 35 that protrudes from the periphery of the second insertion hole 34 is provided on the inner surface of the bearing holder 22 facing the inside of the housing main body 21. A second bearing 36 is held in the second holding portion 35.

[0016] 1 , the output shaft 12 has a first end 41 and a second end 42. The first end 41 is rotatably supported by the first bearing 29, and the second end 42 is rotatably supported by the second bearing 36. As a result, the output shaft 12 is rotatably accommodated within the housing 11. The axis of the output shaft 12 coincides with the axis of the first circumferential wall portion 23. In other words, the axial direction of the output shaft 12 coincides with the axial direction of the motor 2.

[0017] The tip of the first end 41 protrudes outside the housing 11 through the first insertion hole 27. A gear or the like (not shown) is connected to the tip of the first end 41 so as to rotate integrally therewith. A sensor magnet 43 is fixed to the tip of the second end 42 so as to rotate integrally therewith. The sensor magnet 43 is housed in the second insertion hole 34.

[0018] The stator 13 includes a stator core 51, an insulator 52, and a plurality of windings 53. The stator core 51 is fixed to the inner circumferential surface of the first circumferential wall portion 23. Each winding 53 is wound around a tooth of the stator core 51 via the insulator 52. The plurality of windings 53 are divided into a main winding group 53A and a sub-winding group 53B. Each of the main winding group 53A and the sub-winding group 53B has three-phase windings (coils) of U, V, and W. Power is supplied to the main winding group 53A and the sub-winding group 53B independently from each other from the controller 3. Hereinafter, the power supply system for supplying power to the main winding group 53A will be referred to as the main power supply system, and the power supply system for supplying power to the sub-winding group 53B will be referred to as the sub-power supply system.

[0019] The rotor 14 includes a rotor core 54 fixed to rotate integrally with the output shaft 12, and a plurality of motor magnets 55 fixed to the rotor core 54. In the illustrated example, the motor magnets 55 are fixed to the outer peripheral surface of the rotor core 54, but this is not limiting and the motor magnets 55 may be embedded inside the rotor core 54.

[0020] The busbar module 15 is disposed between the bearing holder 22 and the stator 13. The busbar module 15 includes a cylindrical busbar holder 56 and a plurality of busbars 57. In this embodiment, the busbar holder 56 has a circular shape when viewed in the axial direction. The busbar holder 56 is made of a resin material. The busbars 57 are held by the busbar holder 56. The plurality of busbars 57 are divided into main busbars 57A that constitute a main power supply system and sub-busbars 57B that constitute a sub-power supply system. Each main busbar 57A is connected to a corresponding winding 53 of the main winding group 53A. Each sub-busbar 57B is connected to a corresponding winding 53 of the sub-winding group 53B.

[0021] Three-phase AC power is supplied to the main winding group 53A via the main bus bar 57A. This generates a rotating magnetic field in the stator 13, causing the rotor 14 to rotate integrally with the output shaft 12. Similarly, three-phase AC power is supplied to the sub winding group 53B via the sub bus bar 57B. This generates a rotating magnetic field in the stator 13, causing the rotor 14 to rotate integrally with the output shaft 12. In other words, the rotor 14 rotates when power is supplied to at least one of the main winding group 53A and the sub winding group 53B.

[0022] 1 to 3, the controller 3 includes a circuit board 61, a connector 62, and a cover 63. The circuit board 61 has a rectangular plate shape that is slightly smaller than the second peripheral wall portion 26 of the housing 11 when viewed in the axial direction. The circuit board 61 is disposed on the support portion 32 of the housing 11 so that the plate thickness direction is parallel to the axial direction of the motor 2. The circuit board 61 is fixed to the housing 11 by screws 65 being threaded into the screw holes 33 of the support portion 32. In other words, the circuit board 61 is disposed alongside the motor 2 in the axial direction of the motor 2.

[0023] The substrate 61 has a first surface 66 and a second surface 67 that face opposite to each other in the axial direction. The first surface 66 and the second surface 67 are planes perpendicular to the axial direction. The first surface 66 faces the cover 63 in the axial direction, and the second surface 67 faces the flange portion 25, bearing holder 22, and connector 62 of the housing main body 21 in the axial direction. In other words, the cover 63 corresponds to a first part of the motor device 1, and the flange portion 25, bearing holder 22, and connector 62 correspond to a second part of the motor device 1.

[0024] The substrate 61 of this embodiment has a plurality of electronic components mounted on both a first surface 66 and a second surface 67. The substrate 61 has a plurality of through holes and vias (neither of which is shown) for electrically connecting the electronic components mounted on the first surface 66 and the electronic components mounted on the second surface 67. In this way, the substrate 61 has holes that penetrate in the thickness direction, and is configured to allow liquids such as water to pass through the substrate 61.

[0025] As shown in FIG. 2 , the substrate 61 has a main region 61A and a sub-region 61B, which are defined by a first imaginary plane V1 that is perpendicular to the first surface 66 and the second surface 67. The main region 61A and the sub-region 61B are each defined to straddle both the first surface 66 and the second surface 67. The substrate 61 also has a sensor region 61C, which is defined by a second imaginary plane V2 that is perpendicular to the first surface 66 and the second surface 67. The sensor region 61C is defined to straddle both the first surface 66 and the second surface 67. Because the first imaginary plane V1 and the second imaginary plane V2 are perpendicular to the first surface 66 and the second surface 67, the shapes of the main region 61A, the sub-region 61B, and the sensor region 61C on the first surface 66 are the same as the shapes of the main region 61A, the sub-region 61B, and the sensor region 61C on the second surface 67, respectively. In FIG. 2, for the sake of convenience, the first imaginary plane V1 and the second imaginary plane V2 are indicated by two-dot chain lines.

[0026] Specifically, the first imaginary plane V1 is a plane perpendicular to the substrate 61. When viewed from the axial direction, the first imaginary plane V1 extends along the long side of the substrate 61 and is located at the center of the short side of the substrate 61. The second imaginary plane V2 is a cylindrical surface perpendicular to the substrate 61. When viewed from the axial direction, the second imaginary plane V2 in this embodiment has a circular shape. When viewed from the axial direction, the second imaginary plane V2 is positioned so as to surround the sensor magnet 43. In this embodiment, the second imaginary plane V2 intersects with the first imaginary plane V1. The primary region 61A is a region on one side (upper side in FIG. 2 ) of the first imaginary plane V1 on the substrate 61, and the secondary region 61B is a region on the other side (lower side in FIG. 2 ) of the first imaginary plane V1 on the substrate 61. The sensor region 61C is a region surrounded by the second imaginary plane V2 on the substrate 61.

[0027] Various circuits for supplying power to the main winding group 53A and the sub winding group 53B are formed on the substrate 61. Specifically, a main power circuit 71A for supplying power to the main winding group 53A and a main control circuit 72A for outputting control signals for controlling the main power circuit 71A are formed in the main region 61A of the substrate 61. A sub power circuit 71B for supplying power to the sub winding group 53B and a sub control circuit 72B for outputting control signals for controlling the sub power circuit 71B are formed in the sub region 61B of the substrate 61. The main power circuit 71A and the main control circuit 72A constitute a main power supply system, and the sub power circuit 71B and the sub control circuit 72B constitute a sub power supply system.

[0028] The main power circuit 71A is, for example, an inverter circuit. The main power circuit 71A is formed of electronic components including a plurality of switching elements 73A. The switching elements 73A are mounted, for example, on the main area 61A of the second surface 67. The main control circuit 72A is formed of electronic components including a microcomputer 74A. The microcomputer 74A is mounted, for example, on the main area 61A of the first surface 66. The control signal output from the main control circuit 72A switches the switching elements 73A on and off. A connection end 58A of a main bus bar 57A connected to the main winding group 53A is connected to the main area 61A of the substrate 61. The switching elements 73A of the main power circuit 71A are switched on and off based on the control signal output from the microcomputer 74A, thereby converting DC power supplied from a DC power source (not shown) into three-phase AC power. The converted AC power is supplied to the main winding group 53A via the main bus bar 57A.

[0029] The secondary power circuit 71B is, for example, an inverter circuit. The secondary power circuit 71B is formed of electronic components including a plurality of switching elements 73B. The switching elements 73B are mounted, for example, in the secondary region 61B of the second surface 67. The secondary control circuit 72B is formed of electronic components including a microcomputer 74B. The microcomputer 74B is mounted, for example, in the secondary region 61B of the first surface 66. The control signal output by the secondary control circuit 72B switches the switching elements 73B on and off. A connection end 58B of the secondary bus bar 57B connected to the secondary winding group 53B is connected to the secondary region 61B of the substrate 61. The switching elements 73B of the secondary power circuit 71B are switched on and off based on the control signal output from the microcomputer 74B, thereby converting DC power supplied from a DC power source into three-phase AC power. The converted AC power is supplied to the secondary winding group 53B via the secondary bus bar 57B.

[0030] The substrate 61 also includes a main sensor 75A and a sub-sensor 75B mounted thereon for detecting the rotation of the motor 2. The main sensor 75A and the sub-sensor 75B are arranged in a single IC package 76. The IC package 76 is mounted on the second surface 67 of the substrate 61 so as to face the sensor magnet 43 in the axial direction. In other words, the IC package 76 is mounted in the sensor region 61C. The main sensor 75A and the sub-sensor 75B are magnetic sensors, such as MR sensors. Each of the main sensor 75A and the sub-sensor 75B generates an electrical signal corresponding to the direction of the magnetic field applied by the sensor magnet 43, i.e., the rotation angle of the rotor 14. The main sensor 75A outputs the generated electrical signal to the main control circuit 72A, and the sub-sensor 75B outputs the generated electrical signal to the sub-control circuit 72B. The main control circuit 72A and the sub-control circuit 72B generate control signals based on these electrical signals.

[0031] 2 to 4, a capacitor 77A for smoothing the power supplied to the main power circuit 71A and a capacitor 77B for smoothing the power supplied to the sub-power circuit 71B are mounted on the substrate 61. Capacitor 77A is mounted in the main region 61A of the first surface 66. Capacitor 77B is mounted in the sub-region 61B of the first surface 66. Capacitor 77A and capacitor 77B protrude more from the substrate 61 than other electronic components, i.e., they are taller electronic components.

[0032] As shown in FIG. 1 , the connector 62 includes a connector body 81 and a connection terminal 82 connected to a cable (not shown). The connector body 81 is made of, for example, a resin material. The connector body 81 is a rectangular plate larger than the window portion 31 of the housing body 21. The connector body 81 includes a connection port 83 for accommodating the connection terminal 82. The connector 62 does not have a hole penetrating the connector 62, preventing liquid from passing through the connector 62. The connector body 81 is fixed to the flange portion 25 so that the connection port 83 protrudes from the window portion 31. A connector sealant 84 is interposed between the inner periphery of the window portion 31 and the connector body 81. The connector sealant 84 is provided around the entire periphery of the window portion 31, thereby sealing the gap between the window portion 31 and the connector body 81. The connector sealant 84 is made of a waterproof resin material, such as a silicone, epoxy, or polyurethane potting material. The connector sealant 84 preferably has high adhesiveness to the materials of the connector 62 and the housing 11 .

[0033] As shown in FIGS. 1 , 3 , and 4 , the cover 63 is made of, for example, a resin material. The cover 63 has a rectangular box shape with one side open. Specifically, the cover 63 includes a main body 91 and a cover peripheral wall 92 extending axially from the outer periphery of the main body 91. When viewed from the axial direction, the main body 91 has a rectangular shape corresponding to the flange 25. The cover peripheral wall 92 extends axially from the outer periphery of the main body 91 toward the motor 2. The cover peripheral wall 92 extends around the entire periphery of the main body 91. When viewed from the axial direction, the cover peripheral wall 92 in this embodiment has a rectangular shape corresponding to the second peripheral wall 26. Note that the cover 63 does not have a hole penetrating the cover 63, preventing liquid from passing through the cover 63. The cover 63 is fixed to the second peripheral wall 26 so as to close the open end of the housing main body 21. An outer peripheral sealant 93 is interposed between the tip of the cover peripheral wall portion 92 and the tip of the second peripheral wall portion 26. The outer peripheral sealant 93 is provided around the entire periphery of the cover peripheral wall portion 92 and the second peripheral wall portion 26. This seals the gap between the housing main body 21 and the cover 63. The outer peripheral sealant 93 is made of a waterproof resin material, such as a silicone, epoxy, or polyurethane potting material. It is preferable that the outer peripheral sealant 93 have high adhesion to the materials of the cover 63 and the housing 11.

[0034] (Sealing Structure of Board) Next, we will explain the sealing structure of the board 61. The board 61 of this embodiment is sealed so that, even if liquid seeps into the motor device 1, the circuits of the board 61 constituting the first power supply system and the second power supply system will not simultaneously fail.

[0035] 1 to 4, the motor device 1 includes a first seal 101 and a second seal 102 that extend linearly. The first seal 101 is interposed between the substrate 61 and the cover 63. That is, the first seal 101 is sandwiched between the substrate 61 and the cover 63. The second seal 102 is interposed between the substrate 61 and the bearing holder 22 and the connector 62. That is, the second seal 102 is sandwiched between the substrate 61 and the bearing holder 22 and the connector 62.

[0036] 2, the first sealing material 101 has an annular portion 111 and two straight portions 112, 113 extending radially outward from the annular portion 111. The annular portion 111 extends annularly along the second imaginary plane V2. That is, the annular portion 111 is circular when viewed in the axial direction. The two straight portions 112, 113 extend from the intersection of the annular portion 111 with the first imaginary plane V1 to the corresponding edge portions of the substrate 61. In this embodiment, the straight portions 112, 113 extend linearly along the first imaginary plane V1.

[0037] In this way, the primary region 61A and the secondary region 61B are separated from each other by the linear portions 112 and 113 and the annular portion 111. In other words, the linear portions 112 and 113 and the annular portion 111 correspond to the isolation portion. Furthermore, the sensor region 61C is surrounded by the annular portion 111. In other words, the annular portion 111 corresponds to the sensor portion.

[0038] As shown in FIGS. 1, 3, and 4, the cover 63 further includes a first protrusion 94 that protrudes from the main body 91 toward the substrate 61. The first protrusion 94 includes a cylindrical portion 121 and two plate-like portions 122 and 123 that extend radially outward from the cylindrical portion 121. In this embodiment, the cylindrical portion 121 has a circular shape that is the same size as the annular portion 111 when viewed axially. The annular portion 111 of the first seal material 101 is interposed between the tip of the cylindrical portion 121 and the first surface 66 of the substrate 61. The two plate-like portions 122 and 123 extend from the outer peripheral surface of the cylindrical portion 121 along the corresponding linear portions 112 and 113. The linear portions 112 and 113 of the first seal material 101 are interposed between the tips of the plate-like portions 122 and 123 and the first surface 66 of the substrate 61, respectively. This restricts the movement of liquid adhering to the first surface 66 between the main area 61A, the sub-area 61B, and the sensor area 61C on the first surface 66.

[0039] The second sealant 102 has the same shape as the first sealant 101 when viewed in the axial direction. That is, the second sealant 102 has an annular portion 131 that serves as an isolation portion and a sensor portion, and two linear portions 132 and 133 that serve as isolation portions. The annular portion 131, a portion of the linear portion 132, and the linear portion 133 of the second sealant 102 are interposed between the outer surface of the bearing holder 22 and the second surface 67 of the substrate 61. The remaining portion of the linear portion 132 is interposed between the connector body 81 and the second surface 67 of the substrate 61. This restricts the movement of liquid adhering to the second surface 67 between the primary region 61A, the secondary region 61B, and the sensor region 61C on the second surface 67.

[0040] The first seal material 101 and the second seal material 102 are made of a waterproof resin material. In this embodiment, the first seal material 101 and the second seal material 102 are made of the same potting material as the outer periphery seal material 93.

[0041] (Functions and Effects of the Present Embodiment) Next, the functions and effects of the present embodiment will be described. (1-1) The main region 61A and the sub-region 61B of the substrate 61 are separated from each other by the first sealant 101 interposed between the substrate 61 and the cover 63, and the second sealant 102 interposed between the substrate 61 and the bearing holder 22 and the connector 62. Therefore, even if liquid adheres to the main region 61A, the liquid is unlikely to migrate along the substrate 61 to the sub-region 61B. This prevents simultaneous failure of the circuits formed in the main region 61A and the circuits formed in the sub-region 61B. Furthermore, because the first sealant 101 and the second sealant 102 extend linearly, the weight of the motor device 1 can be reduced compared to, for example, applying a waterproof potting material to the entire substrate 61.

[0042] (1-2) The cover 63 has a main body 91 that covers the substrate 61 and a first protrusion 94 that protrudes from the main body 91 toward the substrate 61. The first sealant 101 is interposed between the substrate 61 and the first protrusion 94. Therefore, a large gap is formed between the cover 63 and the substrate 61, while sealing the gap between the cover 63 and the substrate 61. This allows tall electronic components, such as capacitors 77A and 77B, to be mounted on the first surface 66 of the substrate 61.

[0043] (1-3) The motor 2 includes a sensor magnet 43 fixed to the second end 42 of the output shaft 12. The controller 3 includes a primary sensor 75A and a secondary sensor 75B disposed within a single IC package 76. The IC package 76 is mounted in a sensor region 61C of the substrate 61 so as to axially face the sensor magnet 43. The first sealant 101 and the second sealant 102 include annular portions 111, 131 that extend to surround the sensor region 61C.

[0044] According to the above configuration, by arranging the primary sensor 75A and the secondary sensor 75B in a single IC package 76, the primary sensor 75A and the secondary sensor 75B can be arranged close to each other. This prevents the magnetic field of the sensor magnet 43 applied to the primary sensor 75A from differing from the magnetic field of the sensor magnet 43 applied to the secondary sensor 75B. In other words, it prevents the rotation angle of the rotor 14 detected by the primary sensor 75A from differing from the rotation angle of the rotor 14 detected by the secondary sensor 75B. Furthermore, even if liquid adheres to the primary region 61A or the secondary region 61B of the substrate 61, it prevents both the primary sensor 75A and the secondary sensor 75B from failing simultaneously.

[0045] (1-4) The motor device 1 includes an outer periphery sealant 93 interposed between the housing 11 and the cover 63. The first sealant 101, the second sealant 102, and the outer periphery sealant 93 are made of the same potting material.

[0046] According to the above configuration, by applying the first sealant 101 and the second sealant 102 in the same process as the process of applying the outer peripheral sealant 93, the first sealant 101 and the second sealant 102 can be cured substantially simultaneously with the outer peripheral sealant 93. This allows the motor device 1 to be manufactured without having to wait a separate time for the first sealant 101 and the second sealant 102 to cure.

[0047] Second Embodiment Next, a second embodiment of the motor device will be described with reference to the drawings. For the sake of convenience, the same components as those in the first embodiment will be denoted by the same reference numerals, and the description thereof will be omitted.

[0048] 5 to 7 , the first sealing material 101 of this embodiment has, in addition to the annular portion 111 and the linear portions 112 and 113, a frame-shaped portion 114 that extends along the outer periphery of the substrate 61 so as to surround the substrate 61. The frame-shaped portion 114 extends around the entire periphery of the substrate 61. The frame-shaped portion 114 corresponds to the peripheral edge portion. In this embodiment, the frame-shaped portion 114 extends along the outer periphery of the substrate 61 so as not to straddle the heads of the screws 65 by going around the screws 65 where the screws 65 are provided.

[0049] The cover 63 has a second protrusion 124 that protrudes from the main body 91 toward the substrate 61. When viewed in the axial direction, the second protrusion 124 has a frame shape that corresponds to the frame portion 114 of the first sealant 101. The frame portion 114 of the first sealant 101 is interposed between the tip of the second protrusion 124 and the first surface 66 of the substrate 61. This prevents liquid that has entered the motor device 1 from adhering to the first surface 66 of the substrate 61 beyond the first sealant 101.

[0050] When viewed in the axial direction, the second seal material 102 has the same shape as the first seal material 101. That is, the second seal material 102 has a ring-shaped portion 131 and linear portions 132 and 133, as well as a frame-shaped portion 134 that is a peripheral portion.

[0051] An auxiliary portion 141 that protrudes toward the substrate 61 is provided on the flange portion 25 of the housing main body 21. When viewed in the axial direction, the auxiliary portion 141 has a frame shape that corresponds to the frame portion 134 of the second sealant 102. A portion of the auxiliary portion 141 that is adjacent to the support portion 32 is integrated with the support portion 32. The frame portion 134 of the second sealant 102 is interposed between the auxiliary portion 141 and the second surface 67 of the substrate 61. This prevents liquid that has entered the motor device 1 from adhering to the second surface 67 of the substrate 61 over the second sealant 102.

[0052] (Actions and Effects of the Present Embodiment) As described above, the present embodiment provides the following actions and effects in addition to the actions and effects (1-1) to (1-4) of the first embodiment.

[0053] (2-1) The first sealant 101 and the second sealant 102 have frame-shaped portions 114, 134 that extend along the outer periphery of the substrate 61 so as to surround the substrate 61. Therefore, even if liquid seeps in from between the cover 63 and the housing 11, for example, the liquid can be prevented from adhering to the substrate 61.

[0054] The above-described embodiments can be modified as follows. The above-described embodiments and the following modifications can be implemented in combination with each other to the extent that no technical contradiction occurs. In the first embodiment, the first sealant 101 and the second sealant 102 do not need to have a sensor unit. In the example shown in FIGS. 8 and 9 , the first sealant 101 has a semicircular portion 151 instead of the annular portion 111. In the illustrated example, the semicircular portion 151 has a semicircular shape that is convex toward the sub-region 61B. The first protrusion 94 has an arc-shaped portion 152 instead of the cylindrical portion 121. The arc-shaped portion 152 has an arc shape corresponding to the semicircular portion 151 when viewed in the axial direction. The second sealant 102 has a semicircular portion 153 instead of the annular portion 131. When viewed in the axial direction, the semicircular portion 153 has the same shape as the semicircular portion 151. 9, a waterproof potting material 154 is applied to the IC package 76 so as to cover the entire IC package 76. This modification provides the same effects and advantages as those of (1-3) of the first embodiment.

[0055] Similarly, in the second embodiment, the first sealant 101 and the second sealant 102 do not have to have a sensor portion. In the second embodiment, the frame-shaped portion 114 of the first sealant 101 or the frame-shaped portion 134 of the second sealant 102 may be omitted.

[0056] In the above embodiments, the connection port 83 of the connector 62 protrudes from the window 31 of the housing main body 21 to the outside of the motor device 1, but this is not limited to this. For example, the connection port of the connector may protrude from the cover 63 to the outside of the motor device 1. In this case, the cover 63 and the connector 62 correspond to a first portion that faces the first surface 66 of the motor device 1 in the axial direction.

[0057] In each of the above embodiments, the shape of the first sealant 101 can be changed as appropriate as long as it has a separating portion. For example, the straight line portions 112, 113 may extend in a direction inclined with respect to the first imaginary plane V1. Furthermore, the first sealant 101 may have a curved portion curved like a wavy line instead of the straight line portion 112. Similarly, the shape of the second sealant 102 can be changed as appropriate as long as it has a separating portion. In the above second embodiment, the frame-shaped portion 114 of the first sealant 101 may extend along the outer periphery of the substrate 61 so as to straddle the heads of the screws 65.

[0058] In each of the above embodiments, the first seal material 101, the second seal material 102, and the outer periphery seal material 93 may be made of different potting materials. In each of the above embodiments, the first seal material 101 and the second seal material 102 are made of potting materials, but this is not a limitation and they may be made of a rubber material such as an O-ring. Similarly, the outer periphery seal material 93 and the connector seal material 84 may be made of a rubber material such as an O-ring.

[0059] In each of the above embodiments, the substrate 61 does not need to have the sensor region 61C. In this case, the main sensor 75A and the sub-sensor 75B are not arranged in a single IC package 76, but the main sensor 75A is mounted in the main region 61A and the sub-sensor 75B is mounted in the sub-region 61B.

[0060] In each of the above embodiments, the motor device 1 may be used as a power source for a device other than a vehicle steering device.

Claims

1. A motor device comprising: a motor having a main winding group and a secondary winding group; and a controller configured to individually control power supply to the main winding group and the secondary winding group, wherein the motor comprises: a stator having the main winding group and the secondary winding group; a rotor configured to rotate by power supply to at least one of the main winding group and the secondary winding group; an output shaft that rotates integrally with the rotor; and a housing that accommodates the stator, the rotor, and the output shaft, and the controller comprises: a board having first and second faces that face opposite to each other in the axial direction of the output shaft and that is fixed to the housing, and a cover attached to the housing so as to cover the board, the board having a main region and a secondary region defined by an imaginary plane that intersects with the first and second faces, the main region comprising: a main power circuit configured to supply power to the main winding group; and a main control circuit configured to generate a control signal for controlling the main power circuit, and a sub-control circuit configured to generate a control signal for controlling the sub-power circuit, wherein the motor device further includes a first sealant and a second sealant extending linearly, the first sealant being interposed between the substrate and a first portion of the motor device that faces the first surface in the axial direction, and the second sealant being interposed between the substrate and a second portion of the motor device that faces the second surface in the axial direction, and each of the first sealant and the second sealant having an isolation portion extending to separate the main region and the sub-region from each other.

2. A motor device according to claim 1, wherein at least one of the first sealant and the second sealant further has a peripheral edge portion extending along the outer periphery of the substrate so as to surround the substrate.

3. A motor device according to claim 1 or 2, wherein the first part includes the cover, the cover having a main body portion covering the substrate and a protrusion portion protruding from the main body portion toward the substrate, and the first sealing material is interposed between the substrate and the protrusion portion.

4. A motor device according to claim 1 or 2, wherein the motor further comprises a sensor magnet fixed to an end of the output shaft, the controller further comprises a main sensor and an auxiliary sensor arranged in a single IC package, the main sensor is configured to output an electrical signal corresponding to the rotation angle of the rotor to the main control circuit, and the auxiliary sensor is configured to output an electrical signal corresponding to the rotation angle of the rotor to the auxiliary control circuit, the IC package is mounted on the substrate so as to face the sensor magnet in the axial direction, the imaginary surface is a first imaginary surface, the substrate further has a sensor region defined by a cylindrical second imaginary surface that intersects with the first surface and the second surface and surrounds the IC package, and each of the first sealant and the second sealant further includes a sensor portion extending to surround the sensor region.

5. A motor device according to claim 1 or 2, wherein the motor further comprises a sensor magnet fixed to the end of the output shaft, the controller further comprises a main sensor and an auxiliary sensor arranged in a single IC package, the main sensor is configured to output an electrical signal corresponding to the rotation angle of the rotor to the main control circuit, and the auxiliary sensor is configured to output an electrical signal corresponding to the rotation angle of the rotor to the auxiliary control circuit, the IC package is mounted on the substrate so as to face the sensor magnet in the axial direction, and a waterproof potting material is applied to the IC package.

6. A motor device according to claim 1 or 2, further comprising an outer circumferential sealing material interposed between the housing and the cover, wherein the first sealing material, the second sealing material and the outer circumferential sealing material are made of the same potting material.

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