Motor control device

Abstract

A motor control device according to the present invention comprises a power module, a current sensor, and a housing that accommodates the power module and the current sensor. The current sensor comprises: a resin part; a bus bar that is partially embedded in the resin part and that electrically connects a power module and a lead wire; and a sensor part that is embedded in the resin part and detects a current flowing through the bus bar. The bus bar has a first portion that extends in a second direction and passes through a housing hole that penetrates the housing in the second direction, and a second portion that extends from an end of the first portion on one side in the second direction to the other side in a first direction. The first portion has a first protruding part that protrudes from the resin part to the other side in the second direction. The first protruding part is located outside the housing and is fastened to the lead wire. The resin part has a sensor fastening part that is fastened to the housing. The sensor fastening part has a through hole that penetrates the sensor fastening part in the second direction and through which a first fastening member for fastening the sensor fastening part and the housing passes in the second direction.

Description

Motor control device

[0001] The present invention relates to a motor control device.

[0002] An output terminal portion that electrically connects a power conversion portion having a plurality of switching elements and a power wiring of a motor, and a current sensor that detects a current flowing through the output terminal portion are disposed inside a power conversion housing. A power conversion device is known in which the output terminal portion and the power wiring are fastened by a screw member inside the power conversion housing (for example, Japanese Patent Application Laid-Open No. 2023-161545).

[0003] Japanese Patent Application Laid-Open: Japanese Patent Application Laid-Open No. 2023-161545

[0004] In the assembly process of the above power conversion device, in order to fasten the output terminal portion and the power wiring by a screw member inside the power conversion housing through a hole provided in the power conversion housing, after fastening the output terminal portion and the power wiring by a screw member, it is necessary to fix a side cover that closes such a hole to the power conversion housing by a screw member. Therefore, it was difficult to suppress an increase in the assembly man-hours of the power conversion device.

[0005] One aspect of the present invention is to provide a motor control device capable of suppressing an increase in assembly man-hours as one of the objectives.

[0006] One embodiment of the motor control device of the present invention is a motor control device that supplies current to a motor section, comprising: a power module that generates the current supplied to the motor section; a current sensor positioned on one side in the first direction from the power module; and a housing that houses the power module and the current sensor, respectively. The current sensor has a resin part made of resin; a busbar, partly embedded in the resin part, that electrically connects the power module and the lead wires of the motor section; and a sensor part embedded in the resin part that detects the current flowing through the busbar. The busbar has a first portion that extends in a second direction intersecting the first direction and passes through a housing hole that penetrates the housing in the second direction; and a second portion that extends from one end of the first portion in the second direction to the other side in the first direction. The second portion is fastened to the power module. The first portion has a first projection that protrudes from the resin part to the other side in the second direction. The first projection is located outside the housing and is fastened to the lead wires. The resin portion has a sensor fastening portion that is fastened to the housing. The sensor fastening portion has a through hole that penetrates the sensor fastening portion in the second direction, and through which a first fastening member that fastens the sensor fastening portion to the housing passes in the second direction.

[0007] According to one aspect of the present invention, it is possible to suppress an increase in assembly man-hours in a motor control device.

[0008] Figure 1 is a perspective view showing the motor control device of the first embodiment. Figure 2 is a first perspective view showing a part of the motor control device of the first embodiment. Figure 3 is a second perspective view showing a part of the motor control device of the first embodiment. Figure 4 is a cross-sectional view showing the current sensor of the first embodiment. Figure 5 is a cross-sectional view showing the current sensor of the first embodiment, and is a cross-sectional view taken along V-V in Figure 4. Figure 6 is a first perspective view showing the current sensor of the first embodiment. Figure 7 is a second perspective view showing the current sensor of the first embodiment. Figure 8 is a first cross-sectional view showing the assembly process of the motor control device of the first embodiment. Figure 9 is a second cross-sectional view showing the assembly process of the motor control device of the first embodiment. Figure 10 is a third cross-sectional view showing the assembly process of the motor control device of the first embodiment. Figure 11 is a fourth cross-sectional view showing the assembly process of the motor control device of the first embodiment. Figure 12 is a perspective view showing the current sensor of the second embodiment. Figure 13 is a cross-sectional view showing the current sensor of the second embodiment.

[0009] The motor control device according to an embodiment of the present invention will be described below with reference to the drawings. Note that the scope of the present invention is not limited to the following embodiments, and can be arbitrarily modified within the scope of the technical idea of ​​the present invention. Also, in the following drawings, the scale and number of components may differ from the actual structure in order to make the components easier to understand.

[0010] In the following description, the first direction D1 will be shown in each figure as appropriate. In this embodiment, the first direction D1 is the left-right direction of the power converter. The first direction D1 is the direction in which the power module and the current sensor are arranged side by side. In the following description, the side in which the arrow of the first direction D1 points (+D1 side) will be referred to as "one side of the first direction D1" or "right side". The side opposite to the side in which the arrow of the first direction D1 points (-D1 side) will be referred to as "the other side of the first direction D1" or "left side".

[0011] In the following description, the second direction D2 is shown in each figure as appropriate. The second direction D2 is the vertical direction of the power converter. The second direction D2 is the direction that intersects with the first direction D1. In this embodiment, the second direction D2 is perpendicular to the first direction D1. The second direction D2 does not have to be perpendicular to the first direction D1. In the following description, the side to which the arrow of the second direction D2 points (+D2 side) will be referred to as "one side of the second direction D2" or "upper side". The side opposite to the side to which the arrow of the second direction D2 points (-D2 side) will be referred to as "the other side of the second direction D2" or "lower side".

[0012] In the following description, the third direction D3 is shown in each figure as appropriate. The third direction D3 is the front-to-back direction of the power converter. The third direction D3 is the direction that intersects both the first direction D1 and the second direction D2. In this embodiment, the third direction D3 is the direction that is perpendicular to both the first direction D1 and the second direction D2. The third direction D3 does not have to be perpendicular to at least one of the first direction D1 and the second direction D2. In the following description, the side in which the arrow of the third direction D3 points (+D3 side) is referred to as the "front side". The side opposite to the side in which the arrow of the third direction D3 points (-D3 side) is referred to as the "rear side".

[0013] Note that the terms "right side," "left side," "upper side," "lower side," "front side," and "rear side" are merely names used to describe the relative positional relationships of each part, and the actual arrangement may differ from those indicated by these names.

[0014] <First Embodiment> Figure 1 is a perspective view showing the motor control device 10 of this embodiment. The motor control device 10 is a control device that generates a current to be supplied to the motor section 70 (see Figure 4) of the motor, and controls the operation of the motor section 70 by supplying the current to the motor section 70. In this embodiment, the motor control device 10 and the motor are each mounted on a vehicle such as a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHV), or an electric vehicle (EV) to drive the vehicle. As shown in Figure 2, the motor control device 10 comprises a housing 11, a connector section 21, a capacitor module 22, a power module 24, a current sensor 30, and a control board 50.

[0015] The housing 11 is box-shaped and houses the capacitor module 22, power module 24, current sensor 30, and control board 50 inside. In this embodiment, the housing 11 is made of aluminum. The housing 11 may be made of other metal materials such as stainless steel, or of resin material. As shown in Figure 1, the housing 11 has a housing 12 and a lid member 13.

[0016] As shown in Figure 2, the housing 12 is a substantially rectangular tube extending in the second direction D2. The housing 12 may also be a polygonal tube, such as a pentagonal tube, or a cylindrical shape, extending in the second direction D2. Inside the housing 12 are the capacitor module 22, the power module 24, the current sensor 30, and the control board 50. Each of the capacitor module 22, the power module 24, the current sensor 30, and the control board 50 is fixed to the housing 12. The housing 12 has an opening 12a that opens upwards. As shown in Figure 3, the housing 12 has a fixing portion 12b. As shown in Figure 4, the housing 12 is provided with a housing hole 12d.

[0017] As shown in Figure 3, the fixing portion 12b is located on the inside of the side of the housing 12. As shown in Figure 5, in this embodiment, the housing 12 has two fixing portions 12b. Each fixing portion 12b is arranged side by side with a gap between them in the third direction D3. Each fixing portion 12b is provided with a fixing hole 12c that is recessed downward from the upper side of the fixing portion 12b. Each fixing hole 12c is a female screw hole with an internal thread on its inner circumferential surface.

[0018] As shown in Figure 4, the housing hole 12d is a hole that penetrates the housing 12 in the second direction D2. That is, the housing hole 12d is a hole that penetrates the housing 11 in the second direction D2. The housing hole 12d is located near the right end (+D1 side) of the housing 12. As shown in Figure 5, the housing hole 12d is a hole that extends in the third direction D3. Although not shown in the figure, when viewed from the second direction D2, the housing hole 12d is approximately rectangular in shape with its longer side extending in the third direction D3.

[0019] As shown in Figure 1, the lid member 13 is plate-shaped and extends in a direction perpendicular to the second direction D2. Viewed from the second direction D2, the lid member 13 is approximately rectangular in shape. The lid member 13 is fixed to the upper end of the housing 12. As a result, the lid member 13 closes the opening 12a of the housing 12 from above.

[0020] As shown in Figure 2, the connector portion 21 is attached to the housing 12. The connector portion 21 is a roughly rectangular tube that protrudes from the housing 12 to the left (-D1 side). The connector portion 21 holds a plurality of connector pins (not shown). Each connector pin electrically connects an external power supply (not shown) to the capacitor module 22. As a result, a first current C1 is supplied from the external power supply to the capacitor module 22 via the connector portion 21.

[0021] The capacitor module 22 is located in the left (-D1) portion inside the housing 12. The capacitor module 22 has a plurality of capacitors (not shown). Each capacitor is electrically connected to the connector 21 and the power module 24, respectively. Each capacitor smooths the first current C1 supplied to the power module 24 from an external power supply (not shown).

[0022] The power module 24 is located to the right (+D1 side) of the capacitor module 22. The power module 24 is located adjacent to the capacitor module 22 in the first direction D1. The power module 24 generates a second current C2 of a predetermined waveform from a first current C1 supplied by an external power supply (not shown), and supplies the second current C2 to the motor unit 70 (see Figure 4). More specifically, the power module 24 is electrically connected to the U-phase coil, V-phase coil, and W-phase coil (not shown) of the motor unit 70, and supplies phase currents (U-phase current, V-phase current, and W-phase current) to each coil. In this embodiment, the power module 24 converts the first current C1, which is a DC current, into a second current C2, which is an AC current, and supplies it to the motor unit 70. The power module 24 has a power board (not shown) and an output terminal 26 as shown in Figure 3.

[0023] A power board (not shown) has switching elements (not shown). Each switching element generates a second current C2 from a first current C1. In this embodiment, the switching elements are power semiconductor elements such as insulated gate bipolar transistors (IGBTs) and metal-oxide-semiconductor field-effect transistors (MOSFETs). The power board (not shown) has multiple switching elements. As a result, the power module 24 can generate a second current C2, which is a three-phase alternating current.

[0024] The output terminal 26 shown in Figure 3 protrudes to the right (+D1 side) from a power board (not shown). The output terminal 26 is electrically connected to the power board. The output terminal 26 is conductive. The power module 24 has a plurality of output terminals 26. In this embodiment, the power module 24 has three output terminals 26. Each output terminal 26 is spaced apart from each other along the third direction D3. A second current C2 flows through each output terminal 26. More specifically, phase currents of different phases flow through each output terminal 26. As shown in Figure 4, each output terminal 26 is provided with a terminal hole 26a.

[0025] The terminal holes 26a are holes through which the output terminal 26 passes in the second direction D2. Although not shown in the illustration, each terminal hole 26a is approximately circular in shape when viewed from the second direction D2. Each terminal hole 26a is a female screw hole with an internal thread on its inner surface.

[0026] As shown in Figure 3, the current sensor 30 is located in the right (+D1) portion of the inside of the housing 12. The current sensor 30 is located to the right of the power module 24, i.e., on one side in the first direction D1. As shown in Figure 4, in this embodiment, the current sensor 30 is located at a distance from the first inner surface 12g, which is the left (-D1) side of the inner surface of the housing 12. The current sensor 30 faces the first inner surface 12g in the first direction D1. As shown in Figure 6, the dimension of the current sensor 30 in the first direction D1 is smaller than the dimension in the third direction D3. The current sensor 30 in this embodiment is a thin current sensor that is thin in the first direction D1. As shown in Figure 4, the current sensor 30 has a resin part 31, a busbar 40, a sensor part 45, and a terminal part 47.

[0027] The resin part 31 holds the busbar 40, the sensor part 45, and the terminal part 47, respectively. The resin part 31 is made of resin. The resin part 31 is insulating. In this embodiment, the resin part 31 is formed by insert molding, with the busbar 40, the sensor part 45, and the terminal part 47 each being insert members. As shown in Figure 6, the resin part 31 has a first resin part 32, a sensor fastening part 33, a substrate holding part 34, a terminal holding part 35, and a second resin part 37. As shown in Figure 7, the resin part 31 has an opposing surface 31a.

[0028] The first resin portion 32 is the upper part of the resin portion 31. In this embodiment, the first resin portion 32 is a rectangular parallelepiped extending in the second direction D2. Viewed from the second direction D2, the first resin portion 32 is substantially rectangular in shape, with its longer side extending in the third direction D3.

[0029] The sensor fastening portion 33 protrudes from the first resin portion 32 in the third direction D3. When viewed from the second direction D2, the sensor fastening portion 33 has a substantially semicircular shape. As shown in Figure 5, in this embodiment, the resin portion 31 has two sensor fastening portions 33. One sensor fastening portion 33 protrudes from the first resin portion 32 toward the front (+D3 side). The other sensor fastening portion 33 protrudes from the first resin portion 32 toward the rear (-D3 side). Each sensor fastening portion 33 is spaced apart from each other in the third direction D3. Each sensor fastening portion 33 is positioned above different fixing portions 12b. Each sensor fastening portion 33 is provided with a through hole 33a.

[0030] The through-holes 33a are holes that penetrate the sensor fastening portion 33 in the second direction D2. Viewed from the second direction D2, each through-hole 33a is approximately circular in shape. Viewed from the second direction D2, each through-hole 33a coincides with a different fixing hole 12c. A first fastening member 61 is passed through each through-hole 33a in the second direction D2. In this embodiment, each first fastening member 61 is a male screw. Each first fastening member 61 is passed through a different through-hole 33a from above and screwed into a different fixing hole 12c. In this way, each first fastening member 61 fastens the sensor fastening portion 33 to the housing 11. Therefore, the sensor fastening portion 33 is fastened to the housing 11. As a result, the current sensor 30 is fixed to the housing 11.

[0031] The substrate holding portion 34 supports the control board 50 from below, i.e., from the other side of the second direction D2 (-D2 side), and holds the control board 50. As shown in Figure 7, the substrate holding portion 34 is substantially cylindrical in shape and protrudes upward from the upper-facing surface of the first resin portion 32. In this embodiment, the resin portion 31 has two substrate holding portions 34. One substrate holding portion 34 protrudes upward from the front side (+D3 side) of the first resin portion 32. The other substrate holding portion 34 protrudes upward from the rear side (-D3 side) of the first resin portion 32. The substrate holding portions 34 are spaced apart from each other in the third direction D3. As shown in Figure 5, each substrate holding portion 34 is provided with a holding hole 34a.

[0032] The retaining holes 34a are recessed on the lower side of the upper surface of the substrate holding portion 34, that is, on the other side of the second direction D2 (-D2 side). When viewed from the second direction D2, each retaining hole 34a is approximately circular in shape. In this embodiment, each retaining hole 34a is a female screw hole with an internal thread on its inner circumferential surface.

[0033] As shown in Figure 6, the terminal holding portion 35 is a roughly rectangular parallelepiped that protrudes upward from the upper surface of the first resin portion 32. In the third direction D3, the terminal holding portion 35 is positioned between the two substrate holding portions 34. The terminal holding portion 35 faces the control board 50 with a gap in the second direction D2. The terminal holding portion 35 holds the terminal portion 47.

[0034] The second resin part 37 is a roughly rectangular parallelepiped that protrudes downward from the first resin part 32, that is, to the other side of the second direction D2 (-D2 side). Viewed from the second direction D2, the second resin part 37 is a roughly rectangular shape with its long side extending in the third direction D3. The dimension of the second resin part 37 in the second direction D2 is larger than the dimension of the first resin part 32 in the second direction D2. The dimension of the second resin part 37 in the first direction D1 is smaller than the dimension of the first resin part 32 in the first direction D1. As shown in Figures 4 and 5, the second resin part 37 passes through the housing hole 12d in the second direction D2. As a result, the resin part 31 passes through the housing hole 12d in the second direction D2. The lower end of the second resin part 37 is located below the housing hole 12d. As a result, the lower end of the resin part 31 is located below the housing hole 12d. Therefore, the resin part 31 ensures insulation between the busbar 40 and the inner surface of the housing hole 12d.

[0035] As shown in Figure 4, the opposing surface 31a is the right side (+D1 side) of the outer surface of the resin part 31, that is, the surface facing one side in the first direction D1. In this embodiment, the opposing surface 31a faces the first inner surface 12g, which is the left side (-D1 side) of the inner surface of the housing 11, with a gap between them. The opposing surface 31a may be in contact with the first inner surface 12g. In this embodiment, the opposing surface 31a has a first opposing surface 32a, a second opposing surface 37a, and a stepped surface 32c.

[0036] The first opposing surface 32a is the outer surface of the first resin part 32 facing to the right (+D1 side). The second opposing surface 37a is the outer surface of the second resin part 37 facing to the right. In this embodiment, the second opposing surface 37a is located below and to the left (-D1 side) of the first opposing surface 32a. As shown in Figure 7, when viewed from the first direction D1, the first opposing surface 32a and the second opposing surface 37a are each substantially rectangular in shape. As shown in Figure 4, the stepped surface 32c is the outer surface of the first resin part 32 facing downwards, i.e., the other side of the second direction D2 (-D2 side). The right end of the stepped surface 32c is connected to the lower end of the first opposing surface 32a. The left end of the stepped surface 32c is connected to the upper end of the second opposing surface 37a.

[0037] The busbar 40 electrically connects the power module 24 and the lead wire 71 of the motor unit 70. This allows the second current C2 to be supplied from the power module 24 to the motor unit 70 via the busbar 40 and the lead wire 71. Viewed from the third direction D3, the busbar 40 is a roughly L-shaped plate. In this embodiment, the busbar 40 is made of a metal material such as copper. The busbar 40 is electrically conductive. As shown in Figure 6, the current sensor 30 has a plurality of busbars 40. In this embodiment, the current sensor 30 has three busbars 40. The number of busbars 40 in the current sensor 30 may be two or less, or four or more. Each busbar 40 is spaced apart from each other along the third direction D3. Phase currents of different phases flow through each busbar 40. As shown in Figure 4, the busbar 40 has a first portion 41 and a second portion 43.

[0038] The first portion 41 is plate-shaped and extends in the second direction D2. The plate surface of the first portion 41 faces the first direction D1. The first portion 41 has a first embedded portion 41a and a first protruding portion 41b.

[0039] The first embedded portion 41a is the upper part of the first portion 41. The upper end of the first embedded portion 41a is the upper end of the first portion 41. The first embedded portion 41a is the part of the first portion 41 that is embedded in the resin portion 31. The first embedded portion 41a is embedded across the first resin portion 32 and the second resin portion 37. Therefore, a part of the first portion 41 is embedded in the first resin portion 32. Another part of the first portion 41 is embedded in the second resin portion 37. The first embedded portion 41a passes through the housing hole 12d in the second direction D2. As a result, the first portion 41 passes through the housing hole 12d in the second direction D2.

[0040] The first protrusion 41b is the lower part of the first portion 41. The first protrusion 41b protrudes downward from the first embedded portion 41a. The first protrusion 41b is located outside the resin portion 31. The first protrusion 41b protrudes downward from the resin portion 31, that is, to the other side of the second direction D2 (-D2 side). The first protrusion 41b is located below the housing hole 12d. As a result, the first protrusion 41b is located outside the housing 11. The first protrusion 41b has a first fastening portion 41c.

[0041] In this embodiment, the first fastening portion 41c is a hole through which the first protrusion 41b penetrates in the first direction D1. As shown in Figure 5, each first fastening portion 41c is substantially circular in shape when viewed from the first direction D1. As shown in Figure 4, a fourth fastening member 64 is passed through each first fastening portion 41c in the first direction D1. In this embodiment, the fourth fastening member 64 is a male screw. Each fourth fastening member 64 is passed through a different first fastening portion 41c in the first direction D1 and is screwed into a female screw hole in a terminal 71a connected to the lead wire 71. As a result, the first protrusion 41b is fastened to the lead wire 71. In addition, each busbar 40 and the motor portion 70 are electrically connected via the lead wire 71.

[0042] The second portion 43 is plate-shaped and extends from the upper side of the first portion 41, i.e., from one end in the second direction D2 (+D2 side) to the left, i.e., the other end in the first direction D1 (-D1 side). The plate surface of the second portion 43 faces the second direction D2. The second portion 43 has a second embedded portion 43a and a second protruding portion 43b.

[0043] The second embedded portion 43a is a portion on the right side (+D1 side) of the second portion 43. The right end of the second embedded portion 43a is connected to the upper end of the first portion 41. The second embedded portion 43a is the portion of the second portion 43 embedded in the resin portion 31. The second embedded portion 43a is embedded in the first resin portion 32. As described above, the first embedded portion 41a is embedded in the resin portion 31. Thus, a part of each bus bar 40 is embedded in the resin portion 31.

[0044] The second protruding portion 43b is a portion on the left side (-D1 side) of the second portion 43. The second protruding portion 43b protrudes leftward from the second embedded portion 43a. The second protruding portion 43b is disposed outside the resin portion 31. The second protruding portion 43b protrudes leftward from the resin portion 31, that is, to the other side in the first direction D1. As shown in FIG. 3, each second protruding portion 43b is disposed above a different output terminal 26. When viewed from the second direction D2, each second protruding portion 43b overlaps a different output terminal 26. Each second protruding portion 43b is in contact with a different output terminal 26 in the second direction D2. As shown in FIG. 4, the second protruding portion 43b has a hole portion 43c.

[0045] The holes 43c are holes that penetrate the second projection 43b in the second direction D2. Viewed from the second direction D2, each hole 43c is substantially circular in shape. Viewed from the second direction D2, each hole 43c overlaps with the terminal holes 26a of different output terminals 26. A second fastening member 62 is passed through each hole 43c in the second direction D2. In this embodiment, each second fastening member 62 is a male screw. Each second fastening member 62 is passed through different holes 43c from above and screwed into the terminal hole 26a. As a result, each second portion 43 is fastened to the output terminal 26. That is, each second portion 43 is fastened to the power module 24. In addition, each second fastening member 62 fastens the second projection 43b to the output terminal 26. That is, each second fastening member 62 fastens the second projection 43b to the power module 24. As a result, the power module 24 and each busbar 40 are electrically connected. As described above, each busbar 40 and the motor unit 70 are electrically connected via the lead wires 71. Thus, the power module 24 and the motor unit 70 are electrically connected via each busbar 40 and the lead wires 71.

[0046] In this embodiment, as described above, a portion of each of the multiple busbars 40 is embedded in the resin portion 31, and each of the multiple busbars 40 is spaced apart from one another along the third direction D3. Therefore, the resin portion 31 can insulate each busbar 40 from each other. As a result, in this embodiment, a separate member for insulating each busbar 40 from each other is not required, and thus an increase in the number of parts of the motor control device 10 can be suppressed. Consequently, an increase in the manufacturing cost and assembly man-hours of the motor control device 10 can be suppressed.

[0047] In a configuration where the lower end of the resin portion 31 is positioned above the housing hole portion 12d, in order to insulate the bus bar 40 from the inner surface of the housing hole portion 12d, the dimensions of the housing hole portion 12d in the first direction D1 and the third direction D3 may each be increased. However, in this configuration, the housing 11 becomes larger in each of the first direction D1 and the third direction D3. In contrast, in the present embodiment, as described above, since the resin portion 31 can ensure insulation between the bus bar 40 and the inner surface of the housing hole portion 12d, it is possible to suppress an increase in the dimensions of the housing hole portion 12d in the first direction D1 and the third direction D3. Therefore, in each of the first direction D1 and the third direction D3, it is possible to suppress an increase in the size of the housing 11. As a result, it is possible to suppress an increase in the size of the motor control device 10.

[0048] The sensor portion 45 detects the current flowing through the bus bar 40. The sensor portion 45 is embedded in the resin portion 31. In the present embodiment, the sensor portion 45 is embedded in the first resin portion 32. The sensor portion 45 includes a core portion 45a and a sensor substrate 45c.

[0049] As shown in FIG. 5, the core portion 45a is annular and surrounds the bus bar 40. In the present embodiment, the core portion 45a surrounds the second embedded portion 43a. The core portion 45a has magnetism. As the material constituting the core portion 45a, a metal material having a high magnetic permeability such as ferrite and permalloy can be used. The core portion 45a collects the magnetic field generated by the current flowing through the bus bar 40. In the present embodiment, the sensor portion 45 has three core portions 45a. Each core portion 45a surrounds the second embedded portion 43a of a different bus bar 40.

[0050] The sensor substrate 45c is plate-shaped and extends in a direction orthogonal to the second direction D2. The sensor substrate 45c is disposed above each core portion 45a. The sensor substrate 45c is embedded in the first resin portion 32. Three sensors 45d are mounted on the surface of the sensor substrate 45c facing downward.

[0051] Sensor 45d detects the magnetic field generated by the current flowing through the busbar 40. In this embodiment, sensor 45d is a Hall IC. Sensor 45d converts the magnetic field into a voltage and outputs it. The magnitude of the voltage output by sensor 45d correlates with the magnitude of the current flowing through the busbar 40. Each sensor 45d is spaced apart in the third direction D3. Each sensor 45d faces a different core portion 45a in the second direction D2. As a result, each sensor 45d can detect the current value of the second current C2 flowing through each of the three busbars 40.

[0052] As shown in Figure 4, the terminal portion 47 is rod-shaped and extends in the second direction D2. The terminal portion 47 electrically connects the sensor substrate 45c and the control substrate 50. The lower part of the terminal portion 47 is embedded in the terminal holding portion 35 and the first resin portion 32. The lower end of the terminal portion 47 is connected to the sensor substrate 45c. In this way, the terminal portion 47 is electrically connected to the sensor 45d. The upper part of the terminal portion 47 protrudes upward from the terminal holding portion 35. In other words, the terminal portion 47 protrudes upward from the resin portion 31, i.e., to one side of the second direction D2 (+D2 side). The upper part of the terminal portion 47 is connected to the control substrate 50. As shown in Figure 7, an elastically deformable portion 47a is provided in the upper part of the terminal portion 47.

[0053] The elastically deformable portion 47a has a substantially elliptical shape with its major axis extending in the second direction D2. The elastically deformable portion 47a is provided with a hole that penetrates through it in the first direction D1. This allows the elastically deformable portion 47a to be elastically deformable in the third direction D3. The elastically deformable portion 47a may also be provided with a hole that penetrates through it in the third direction D3. In this case, the elastically deformable portion 47a can be elastically deformed in the first direction D1. In this embodiment, the current sensor 30 has five terminal portions 47. Each terminal portion 47 is spaced apart from each other along the third direction D3.

[0054] As shown in Figure 2, the control board 50 is plate-shaped and extends in a direction perpendicular to the second direction D2. Viewed from the second direction D2, the control board 50 is substantially rectangular in shape, with its longer side extending in the first direction D1. As shown in Figures 2 and 4, the control board 50 is positioned above the power module 24 and the current sensor 30, i.e., on one side of the second direction D2 (+D2 side). As shown in Figure 4, the control board 50 is electrically connected to the sensor unit 45 via each terminal portion 47. The control board 50 is electrically connected to a power board (not shown) of the power module 24. The control board 50 controls the operation of a plurality of switching elements mounted on the power board based on the current value flowing through each busbar 40 detected by the sensor 45d and the target value of the current flowing through each busbar 40. This reduces the difference between the current value flowing through each busbar 40 and the target current value. The control board 50 has substrate holes 51 and through holes 52.

[0055] The substrate holes 51 are holes that penetrate the control board 50 in the second direction D2. Although not shown in the illustration, in this embodiment the control board 50 has two substrate holes 51. Each substrate hole 51 is spaced apart from each other along the third direction D3. Although not shown in the illustration, when viewed from the second direction D2, each substrate hole 51 overlaps with different retaining holes 34a. The lower surface of the control board 50 is in contact with each substrate retaining part 34 in the second direction D2. This determines the position of the control board 50 in the second direction D2 relative to the current sensor 30. A third fastening member 63 is passed through each substrate hole 51 in the second direction D2. In this embodiment each third fastening member 63 is a male screw. Each third fastening member 63 is passed through different substrate holes 51 from above and screwed into the retaining hole 34a. As a result, the control board 50 is fixed to the board holder 34 by the third fastening member 63.

[0056] A through-hole 52 is a hole that penetrates the control board 50 in the second direction D2. The inner circumferential surface of the through-hole 52 is plated with a conductive material such as copper. Although not shown in the figures, in this embodiment the control board 50 has five through-holes 52. Each through-hole 52 is spaced apart from each other along the third direction D3. Different terminal portions 47 are passed through each through-hole 52 in the second direction D2. A part of the elastically deformable portion 47a is located inside each through-hole 52. As described above, the elastically deformable portion 47a is elastically deformable in the third direction D3. Inside each through-hole 52, a part of the elastically deformable portion 47a is elastically deformed inward in the third direction D3. Therefore, the elastically deformable portion 47a is press-fitted into the through-hole 52 by the restoring force of the elastically deformable portion 47a facing outward in the third direction D3. As a result, the elastically deformable portion 47a is electrically connected to the inner circumferential surface of the through-hole 52, and each terminal portion 47 is electrically connected to the control board 50. Therefore, the sensor portion 45 is electrically connected to the control board 50 via each terminal portion 47.

[0057] Next, the assembly process of the motor control device 10 of this embodiment will be described. The assembly process of the motor control device 10 of this embodiment includes a molding process P01 for manufacturing the current sensor 30 by insert molding, a first fastening process P02 for fastening the current sensor 30 to the housing 11, a second fastening process P03 for fastening the bus bar 40 to the power module 24, a third fastening process P04 for fastening the lead wires 71 to the bus bar 40, a fourth fastening process P05 for fastening the control board 50 to the substrate holding part 34, and a lid member fixing process P06 for fixing the lid member 13 to the housing 12. The assembly process of the motor control device 10 may also include other processes such as fixing the connector part 21, the capacitor module 22, and the power module 24 to the housing 11. Note that the order of each process is not limited to the above order, and for example, the second fastening process P03 may be a process after the third fastening process P04 and before the fourth fastening process P05. Furthermore, the third fastening step P04 may be a later step than both the fourth fastening step P05 and the lid member fixing step P06. In the following description, "workers, etc." includes workers and assembly equipment, etc., who perform the work in each step. The work in each step may be performed by workers alone, by assembly equipment alone, or by workers and assembly equipment.

[0058] In molding process P01, the worker manufactures the current sensor 30 by insert molding. Although not shown in the diagram, the worker molds the resin part 31 by insert molding, using the busbar 40, sensor part 45, and terminal part 47 as insert members. As a result, as shown in Figure 8, a current sensor 30 is manufactured in which the lower part of the sensor part 45 and terminal part 47, and a part of the busbar 40 are embedded in the resin part 31. Once the manufacturing of the current sensor 30 is complete, molding process P01 is completed.

[0059] In the first fastening step P02, the worker fastens the current sensor 30 to the housing 11. The worker moves the current sensor 30, which is positioned above the housing 12 to which the connector portion 21, capacitor module 22, and power module 24 are fixed, downward. This allows the worker to insert the current sensor 30 into the right side (+D1 side) of the inside of the housing 12 through the opening 12a. As shown in Figure 9, the worker moves the current sensor 30 downward until each sensor fastening portion 33 of the current sensor 30 contacts a different fixing portion 12b in the second direction D2, at which point the downward movement of the current sensor 30 is completed. At this time, the first protrusion 41b and the second resin portion 37 of each bus bar 40 are passed through the housing hole 12d in the second direction D2. As a result, the first protrusion 41b of each bus bar 40 is located outside the housing 11.

[0060] Next, the worker adjusts the position of the current sensor 30 in the first direction D1 and the third direction D3 so that, when viewed from the second direction D2, each through hole 33a aligns with a different fixing hole 12c. Next, the worker inserts each first fastening member 61 into the housing 12 from above through the opening 12a, passes each first fastening member 61 through the different through holes 33a from above, and tightens them into the fixing holes 12c. This fastens the current sensor 30 to the housing 11. Once the worker fastens the current sensor 30 to the housing 11, the first fastening step P02 is completed.

[0061] In the second fastening step P03, the worker fastens the busbars 40 to the power module 24. As shown in Figure 10, the worker inserts each second fastening member 62 into the housing 12 from above through the opening 12a, passes each second fastening member 62 through different holes 43c from above, and tightens them into the terminal holes 26a. As a result, each busbar 40 is fastened to different output terminals 26. In other words, each busbar 40 is fastened to the power module 24. This electrically connects each busbar 40 to the power module 24. Once the worker fastens the busbars 40 to the power module 24, the second fastening step P03 is completed.

[0062] In the third fastening step P04, the worker fastens the lead wires 71 to the busbars 40. As shown in Figure 10, below the housing 11, that is, outside the housing 11, the worker passes each fourth fastening member 64 through different first fastening portions 41c from the left side (-D1 side) and tightens them into the female screw holes of different terminals 71a. This fastens different lead wires 71 to each busbar 40. Therefore, each busbar 40 is electrically connected to the motor unit 70 via the lead wires 71. Thus, the power module 24 and the motor unit 70 are electrically connected via each busbar 40 and lead wire 71. Once the worker fastens the lead wires 71 to the busbars 40, the third fastening step P04 is completed.

[0063] In the fourth fastening step P05, the worker fastens the control board 50 to the substrate holder 34. First, the worker moves the control board 50, which is positioned above the housing 12, downward so that, as shown in Figure 11, the control board 50 is inserted into the housing 12 through the opening 12a. Next, the worker moves the control board 50 downward while inserting different terminal portions 47 into each through-hole 52 of the control board 50. When the downward-facing surface of the control board 50 comes into contact with each substrate holder 34 in the second direction D2, the worker stops moving the control board 50 downward. At this time, since the elastic deformation portion 47a of each terminal portion 47 is located inside the through-hole 52, each terminal portion 47 is press-fitted into the through-hole 52 as described above. As a result, each terminal portion 47 is electrically connected to the control board 50 as described above. Therefore, the sensor portion 45 is electrically connected to the control board 50 via each terminal portion 47. Next, although not shown in the diagram, the operator connects the control board 50 to the power board of the power module 24. This electrically connects the sensor unit 45 to the power module 24.

[0064] Next, the worker inserts each third fastening member 63 into the housing 12 from above through the opening 12a, passes each third fastening member 63 through different substrate holes 51 from above, and tightens them into the retaining holes 34a. As a result, the control board 50 is fastened to each substrate retaining part 34. In other words, the control board 50 is fastened to the current sensor 30. Once the worker fastens the control board 50 to the substrate retaining part 34, the fourth fastening step P05 is completed.

[0065] In the lid fixing step P06, the worker fixes the lid member 13 to the housing 12. As shown in Figure 1, the worker fixes the lid member 13 to the upper end of the housing 12 from the upper side of the housing 12. In this embodiment, the lid member 13 is adhesively fixed to the housing 12. The lid member 13 may also be fixed to the housing 12 by welding or by fasteners such as screws. Once the worker has fixed the lid member 13 to the housing 12, the lid fixing step P06 is completed. When the lid fixing step P06 is completed, the assembly process of the motor control device 10 is completed, and the motor control device 10 shown in Figures 1 to 5 is completed.

[0066] According to this embodiment, the current sensor 30 includes a resin part 31 made of resin, a busbar 40 which is partially embedded in the resin part 31 and electrically connects the power module 24 and the lead wires 71 of the motor part 70, and a sensor part 45 which is embedded in the resin part 31 and detects the current flowing through the busbar 40. The busbar 40 has a first part 41 which extends in a second direction D2 and passes through a housing hole 12d which penetrates the housing 11 in the second direction D2, and a second part 43 which extends to the left from the upper end of the first part 41, i.e., one end on the second direction D2 (+D2 side), i.e., the other end on the first direction D1 (-D1 side). The first part 41 has a first projection 41b which protrudes downward from the resin part 31. The first projection 41b is located outside the housing 11 and is fastened to the lead wires 71. When the first protrusion 41b is located inside the housing 11, the first fastening portion 41c of the first protrusion 41b and the lead wire 71 must be fastened together by the first fastening member 61 inside the housing 11 through a hole provided in the housing 11. In this case, after fastening the first fastening portion 41c and the lead wire 71 with the first fastening member 61, a cover to close the hole must be fixed to the housing 11. Therefore, it was difficult to suppress the increase in assembly man-hours for the motor control device 10. In contrast, in this embodiment, as described above, in the first fastening step P02, the first protrusion 41b can be passed through the housing hole 12d by a simple operation of moving the current sensor 30 downwards. As a result, the first fastening portion 41c can be positioned outside the housing 11, and in the third fastening step P04, the first fastening portion 41c and the lead wire 71 can be fastened outside the housing 11. Therefore, in this embodiment, there is no need to provide a hole in the housing 11 for fastening the first fastening portion 41c and the lead wire 71 with the first fastening member 61. Consequently, the work of fixing a cover to close such a hole to the housing 11 is unnecessary, and thus the increase in assembly man-hours for the motor control device 10 can be suppressed.

[0067] According to this embodiment, the resin part 31 has a sensor fastening part 33 that is fastened to the housing 11, and the sensor fastening part 33 has a through hole 33a that penetrates the sensor fastening part 33 in a second direction D2, and through which a first fastening member 61 that fastens the sensor fastening part 33 to the housing 11 passes in the second direction D2. Therefore, as described above, in the first fastening step P02, after inserting the current sensor 30 into the housing 12 from above through the opening 12a, the first fastening member 61 can be inserted into the housing 12 from above through the opening 12a, and the first fastening member 61 can be passed through the through hole 33a from above and tightened into the fixing hole 12c. Therefore, in the first fastening step P02, the current sensor 30 can be fixed to the housing 11 by work performed only from above. This makes it possible to suitably improve the workability for fixing the current sensor 30 to the housing 11 in the first fastening step P02. Therefore, the increase in assembly man-hours for the motor control device 10 can be more effectively suppressed.

[0068] According to this embodiment, the second portion 43 has a second projection 43b that protrudes from the resin portion 31 to the left (-D1 side), i.e., to the other side of the first direction D1. The second projection 43b has a hole 43c that penetrates the second projection 43b in the second direction D2, and through which the second fastening member 62, which fastens the second projection 43b to the power module 24, passes in the second direction D2. Therefore, as described above, in the second fastening step P03, the second fastening member 62 can be inserted into the housing 12 from above through the opening 12a, and the second fastening member 62 can be passed through the hole 43c from above and tightened into the terminal hole 26a. As a result, in the second fastening step P03, the busbar 40 can be fastened to the power module 24 by work performed only from above. Therefore, in both the first fastening step P02 and the second fastening step P03, the current sensor 30 can be fixed to the housing 11 and the busbar 40 can be fastened to the power module 24 by work performed only from above. This allows for a favorable improvement in the workability of the first fastening step P02 and the second fastening step P03. Consequently, the increase in assembly man-hours for the motor control device 10 can be more favorably suppressed.

[0069] According to this embodiment, the resin portion 31 passes through the housing hole 12d in the second direction D2, and the lower end of the resin portion 31, i.e., the other end in the second direction D2, is located below the housing hole 12d. Therefore, as described above, the resin portion 31 ensures insulation between the busbar 40 and the inner surface of the housing hole 12d. This eliminates the need for a separate member to insulate the busbar 40 from the housing 11. As a result, the increase in the number of parts of the motor control device 10 can be more effectively suppressed. Consequently, the increase in the manufacturing cost and assembly man-hours of the motor control device 10 can be more effectively suppressed.

[0070] According to this embodiment, the motor control device 10 includes a control board 50 positioned above the current sensor 30, i.e., on one side of the second direction D2 (+D2 side). The current sensor 30 has a terminal portion 47 that is electrically connected to a sensor portion 45 and protrudes upward from the resin portion 31. The control board 50 has a through-hole 52 through which the terminal portion 47 passes in the second direction D2. Therefore, as described above, in the fourth fastening step P05, the terminal portion 47 can be passed through the through-hole 52 by simply moving the control board 50, which is positioned above the housing 12, downward. Consequently, even in the fourth fastening step P05, the terminal portion 47 can be passed through the through-hole 52 by only working from above, thus more effectively suppressing an increase in the assembly man-hours of the motor control device 10.

[0071] In this embodiment, the terminal portion 47 is press-fitted into the through-hole 52. Therefore, in the fourth fastening step P05, the terminal portion 47 and the through-hole 52 can be electrically connected by simply moving the control board 50 downwards and passing the terminal portion 47 through the through-hole 52. Thus, compared to a configuration in which the terminal portion 47 and the through-hole 52 are electrically connected by solder or the like, the increase in assembly man-hours for the motor control device 10 can be more effectively suppressed.

[0072] According to this embodiment, the resin portion 31 has a substrate holding portion 34 that supports the control substrate 50 from below, that is, from the other side of the second direction D2 (-D2 side). Therefore, in the fourth fastening step P05, the position of the control substrate 50 in the second direction D2 can be determined by only a simple operation of moving the control substrate 50 downward and bringing the control substrate 50 and the substrate holding portion 34 into contact in the second direction D2. Thus, the increase in assembly man-hours of the motor control device 10 can be more effectively suppressed.

[0073] According to this embodiment, the substrate holding portion 34 is provided with a retaining hole 34a recessed on the lower side, i.e., on the other side of the second direction D2 (-D2 side), and the control board 50 is provided with a substrate hole portion 51 that penetrates the control board 50 in the second direction D2. The control board 50 is fixed to the substrate holding portion 34 by a third fastening member 63 that passes through the substrate hole portion 51 in the second direction D2 and is tightened into the retaining hole 34a. Therefore, as described above, in the fourth fastening step P05, the third fastening member 63 can be inserted into the housing 12 from above through the opening 12a, and the third fastening member 63 can be passed through the substrate hole portion 51 from above and tightened into the retaining hole 34a. As a result, even in the fourth fastening step P05, the control board 50 can be fastened to the substrate holding portion 34 by work performed only from above. Therefore, the increase in assembly man-hours for the motor control device 10 can be more effectively suppressed.

[0074] According to this embodiment, the resin portion 31 has an opposing surface 31a facing to the right, i.e., one side of the first direction D1 (+D1 side), and the opposing surface 31a faces the inner surface of the housing 11 with a gap between them. Therefore, in the first fastening step P02, it is easier to prevent the resin portion 31 from coming into contact with the housing 12 when inserting the current sensor 30 into the housing 12. As a result, the current sensor 30 can be easily inserted into the housing 12, improving the workability of inserting the current sensor 30 into the housing 12. Therefore, since the number of work steps in the first fastening step P02 can be suppressed, the number of assembly steps for the motor control device 10 can be more effectively suppressed.

[0075] Furthermore, in this embodiment, as described above, the opposing surface 31a faces the inner surface of the housing 11 with a gap between them. Therefore, vibrations of the vehicle on which the motor control device 10 is mounted, and vibrations of the motor section 70 to which the motor control device 10 is connected, can be effectively suppressed from being transmitted to the current sensor 30 via the housing 11. This effectively suppresses the disconnection of the terminal section 47 and the lead wires 71, etc., due to such vibrations. In addition, since rotation of each fastening member, such as the second fastening member 62 and the fourth fastening member 64, due to such vibrations can be suppressed, a decrease in the fastening force of each fastening member can be suppressed. Therefore, the stability of the electrical connections between each part constituting the motor control device 10 can be effectively improved during the operation of the motor control device 10. This effectively improves the reliability of the operation of the motor control device 10.

[0076] According to this embodiment, the resin portion 31 has a first resin portion 32 in which a part of the first portion 41 and the sensor portion 45 are embedded, and a second resin portion 37 in which the other part of the first portion 41 is embedded. The second resin portion 37 protrudes downward from the first resin portion 32, i.e., to the other side in the second direction (-D2 side), and the dimension of the second resin portion 37 in the first direction D1 is smaller than the dimension of the first resin portion 32 in the first direction D1. Only a part of the first portion 41 is embedded in the second resin portion 37, and the sensor portion 45 is not embedded. Therefore, the dimension of the second resin portion 37 in the first direction D1 can be made smaller than the dimension of the first resin portion 32 in the first direction D1. As a result, the volume of the resin portion 31 can be reduced compared to a configuration in which the dimension of the second resin portion 37 in the first direction D1 is greater than or equal to the dimension of the first resin portion 32 in the first direction D1. Therefore, the material cost of the resin portion 31 can be reduced, and thus the increase in the manufacturing cost of the current sensor 30 can be suppressed.

[0077] <Second Embodiment> As shown in Figure 12, the current sensor 230 of this embodiment has a protruding portion 239. In the following description, components that are the same as those in the first embodiment described above are denoted by the same reference numerals, and their descriptions are omitted.

[0078] As shown in Figure 13, the current sensor 230 of this embodiment has a resin part 231, a busbar 40, a sensor part 45, and a terminal part 47. The resin part 231 holds the busbar 40, the sensor part 45, and the terminal part 47, respectively. As shown in Figure 12, the resin part 231 has a first resin part 32, a sensor fastening part 33, a substrate holding part 34, a terminal holding part 35, a second resin part 37, an opposing surface 31a, and a protruding part 239.

[0079] Similar to the first embodiment described above, the opposing surface 31a is the right side of the outer surface of the resin portion 231, that is, the surface facing one side of the first direction D1 (+D1 side). As shown in Figure 13, the opposing surface 31a faces the first inner surface 12g of the housing 11 with a gap in the first direction D1. The opposing surface 31a has a first opposing surface 32a, a second opposing surface 37a, and a stepped surface 32c. As shown in Figure 12, a projection 239 is provided on the opposing surface 31a.

[0080] The projection 239 is rib-shaped, protruding to the right from the opposing surface 31a, i.e., to one side of the first direction D1 (+D1 side), and extending in the second direction D2. The projection 239 extends in the second direction D2, straddling the first opposing surface 32a and the second opposing surface 37a. In the second direction D2, the upper end of the projection 239 is at the same position as the upper end of the first opposing surface 32a. The upper end of the projection 239 may be located below the upper end of the first opposing surface 32a. The lower end of the projection 239 is located above the lower end of the second opposing surface 37a. As shown in Figure 13, the lower end of the projection 239 is located inside the housing 12.

[0081] In this embodiment, the right end of the projection 239 is tapered, located to the right as it is directed upward, i.e., toward one side of the second direction D2 (+D2 side). Viewed from the third direction D3, the right end of the projection 239 is straight, passing to the right of the stepped surface 32c. As shown in Figure 12, in this embodiment, two projections 239 are provided on the opposing surface 31a. Each projection 239 is provided spaced apart from each other in the third direction D3. The number of projections 239 provided on the opposing surface 31a may be one or three or more. Also, as viewed from the third direction D3, the right end of the projection 239 may be a curved shape passing to the right of the stepped surface 32c, or a straight shape extending in the second direction D2, or other shapes. As shown in Figure 13, in this embodiment, the upper end of each projection 239 is in contact with the first inner surface 12g of the housing 12. In other words, a portion of each protrusion 239 is in contact with the inner surface of the housing 11. The other configurations of the resin part 231 in this embodiment are the same as the other configurations of the resin part 31 in the first embodiment described above. The other configurations of the motor control device 210 in this embodiment are the same as the other configurations of the motor control device 10 in the first embodiment described above. The assembly process of the motor control device 210 in this embodiment is the same as the assembly process of the motor control device 10 in the first embodiment described above.

[0082] According to this embodiment, the resin portion 231 faces to the right, i.e., one side of the first direction D1 (+D1 side), and has an opposing surface 31a facing the first inner surface 12g of the housing 11. The opposing surface 31a is provided with a projection 239 that protrudes to the right and extends in the second direction D2. Therefore, the projection 239 prevents the opposing surface 31a from coming into contact with the first inner surface 12g. As a result, for example, the entire first opposing surface 32a is prevented from coming into contact with the first inner surface 12g, thus preventing an increase in the contact area between the resin portion 231 and the housing 11. Therefore, vibrations of the vehicle on which the motor control device 210 is mounted, and vibrations of the motor section 70 to which the motor control device 10 is connected, can be effectively prevented from being transmitted to the current sensor 230 via the housing 11. As a result, disconnection of the terminal section 47 and the lead wire 71, etc., due to such vibrations can be effectively prevented. Furthermore, since the rotation of each fastening member, such as the second fastening member 62 and the fourth fastening member 64, due to such vibrations can be effectively suppressed, a decrease in the fastening force provided by each fastening member can be effectively suppressed. Therefore, the stability of the electrical connections between the various parts constituting the motor control device 210 can be effectively improved during the operation of the motor control device 210. This effectively improves the reliability of the operation of the motor control device 210.

[0083] In this embodiment, a portion of the protrusion 239 is in contact with the first inner surface 12g of the housing 11. Therefore, in the first fastening step P02, after the current sensor 230 has finished moving downward, the current sensor 230 is moved to the right (+D1 side) until a portion of the protrusion 239 is in contact with the first inner surface 12g, thereby accurately determining the position of the current sensor 230 in the first direction D1 relative to the housing 11. This makes it easier to accurately determine the position of the holes 43c provided in each bus bar 40 relative to the terminal holes 26a provided in each output terminal 26. Therefore, in the second fastening step P03, the second fastening member 62 can more easily fasten each output terminal 26 to each bus bar 40. Consequently, the increase in the number of work steps in the second fastening step P03 can be more effectively suppressed, and thus the increase in the number of work steps for assembling the motor control device 210 can be more effectively suppressed.

[0084] According to this embodiment, the right end of the protrusion 239, that is, the end on one side in the first direction D1 (+D1 side), is located to the right as it moves upward, that is, toward one side in the second direction D2 (+D2 side). Therefore, in the first fastening step P02, when inserting the current sensor 230 into the housing 12 through the opening 12a by moving the current sensor 230 downward, it is easier to prevent the protrusion 239 from catching on the upper end of the housing 12. This makes it easier to insert the current sensor 230 into the housing 12. Consequently, the increase in the number of work steps in the second fastening step P03 can be more effectively suppressed, and therefore the increase in the number of work steps for assembling the motor control device 210 can be more effectively suppressed.

[0085] According to this embodiment, the opposing surface 31a has a stepped surface 32c facing downward, i.e., the other side of the second direction D2 (-D2 side), and when viewed from the third direction D3, the right end of the protrusion 239, i.e., one side of the first direction D1 (+D1 side), is a straight line passing to the right of the stepped surface 32c. Therefore, in the first fastening step P02, when inserting the current sensor 230 into the housing 12 through the opening 12a by moving the current sensor 230 downward, it is possible to prevent the stepped surface 32c from catching on the upper end of the housing 12. This makes it easier to insert the current sensor 230 into the housing 12. Consequently, the increase in the number of work steps in the second fastening step P03 can be more effectively suppressed, and therefore the increase in the number of work steps for assembling the motor control device 210 can be more effectively suppressed.

[0086] The present invention is not limited to the embodiments described above, and other configurations and methods can be adopted within the scope of the technical idea of ​​the present invention. For example, the method of fastening the second protrusion and the output terminal is not limited to this embodiment; for example, the second protrusion and the output terminal may be fastened by welding. Even in this case, in the second fastening step, the busbar can be fastened to the power module by work performed only from above. Therefore, the workability of the first and second fastening steps can be suitably improved. Therefore, the increase in assembly man-hours for the motor control device can be more suitably suppressed.

[0087] Furthermore, the method of fastening the first protrusion and the lead wire is not limited to this embodiment; for example, the first protrusion and the lead wire may be fastened by welding. In this case as well, in the third fastening step, the first fastening part and the lead wire can be fastened outside the housing. Therefore, there is no need to provide a hole in the housing for fastening the first fastening part and the lead wire with the first fastening member. In this configuration, the first protrusion does not need to have the first fastening part.

[0088] Furthermore, the dimension of the second resin part in the first direction may be the same as the dimension of the first resin part in the first direction. In this case, since the opposing surface does not have a stepped surface, it is easier to prevent the resin part from getting caught on the upper end of the housing when inserting the current sensor into the housing during the first fastening process. This makes it easier to insert the current sensor into the housing.

[0089] Furthermore, the motor control device may include multiple power modules and multiple current sensors. This allows the motor control device to supply current to multiple motor sections.

[0090] Furthermore, the second resin part 37 may be fitted with an O-ring that surrounds the second resin part 37 from the first and second directions and contacts the first inner surface. The O-ring is preferably made of rubber. This allows for accurate determination of the first position of the current sensor relative to the housing, making it easier to accurately determine the position of the holes provided in each busbar relative to the terminal holes provided in each output terminal. Therefore, in the second fastening step, each output terminal and each busbar can be easily fastened by the second fastening member. In addition, the O-ring can absorb vibrations transmitted from the housing to the current sensor, thus effectively suppressing a decrease in the fastening force by each fastening member, as described above. Furthermore, the O-ring makes it possible to completely seal the housing hole 12d. This ensures the airtightness of the housing 11, thus preventing dust and other debris, as well as moisture, from entering the inside of the housing 11.

[0091] Although embodiments of the present invention have been described above, the configurations and combinations thereof in the embodiments are merely examples, and additions, omissions, substitutions, and other modifications are possible without departing from the spirit of the present invention. Furthermore, the present invention is not limited by the embodiments.

[0092] Furthermore, this technology can be configured as follows: (1) A motor control device that supplies current to a motor section, comprising: a power module that generates the current supplied to the motor section; a current sensor positioned on one side of the power module in the first direction; and a housing that houses the power module and the current sensor, respectively, wherein the current sensor comprises: a resin part made of resin; a busbar, partly embedded in the resin part, that electrically connects the power module and the lead wires of the motor section; and a sensor part, embedded in the resin part, that detects the current flowing through the busbar, wherein the busbar extends in a second direction intersecting the first direction and penetrates the housing in the second direction A motor control device having a first portion that passes through a housing hole and a second portion that extends from one end of the first portion in the second direction to the other end in the first direction, the second portion being fastened to the power module, the first portion having a first projection that protrudes from the resin portion to the other end in the second direction, the first projection being located outside the housing and fastened to the lead wire, the resin portion having a sensor fastening portion that is fastened to the housing, the sensor fastening portion having a through hole that penetrates the sensor fastening portion in the second direction and through which a first fastening member that fastens the sensor fastening portion to the housing passes in the second direction. (2) The motor control device according to (1), wherein the second portion has a second projection that protrudes from the resin portion to the other end in the first direction, the second projection has a hole that penetrates the second projection in the second direction and through which a second fastening member that fastens the second projection to the power module passes in the second direction. (3) The motor control device according to (1) or (2), wherein the resin portion is passed through the housing hole in the second direction, and the other end of the resin portion in the second direction is located on the other side of the housing hole in the second direction. (4) The motor control device according to any one of (1) to (3), comprising a control board located on one side of the current sensor in the second direction, wherein the current sensor is electrically connected to the sensor portion and has a terminal portion that protrudes from the resin portion on one side of the second direction, and the control board has a through hole through which the terminal portion passes in the second direction.(5) The motor control device according to (4), wherein the terminal portion is press-fitted into the through-hole. (6) The motor control device according to (4) or (5), wherein the resin portion has a substrate holding portion that supports the control board from the other side in the second direction. (7) The motor control device according to (6), wherein the substrate holding portion is provided with a retaining hole recessed to the other side in the second direction, the control board is provided with a substrate hole portion that penetrates the control board in the second direction, and the control board is fixed to the substrate holding portion by a third fastening member that passes through the substrate hole portion in the second direction and is tightened into the retaining hole. (8) The motor control device according to any one of (1) to (7), wherein the resin portion has opposing surfaces facing one side in the first direction, and the opposing surfaces face the inner surface of the housing at a distance from it. (9) The motor control device according to any one of (1) to (7), wherein the resin portion has a facing surface that faces one side in the first direction and faces the inner surface of the housing, and the facing surface is provided with a projection that protrudes to one side in the first direction and extends in the second direction. (10) The motor control device according to (9), wherein a part of the projection is in contact with the inner surface of the housing. (11) The motor control device according to (9) or (10), wherein the end of the projection on one side in the first direction is located on one side in the first direction as it moves toward one side in the second direction. (12) The motor control device according to any one of (9) to (11), wherein the facing surface has a stepped surface that faces the other side in the second direction, and when viewed from a third direction that intersects both the first and second directions, the end of the projection on one side in the first direction is in a straight line that passes to one side in the first direction than the stepped surface. (13) The motor control device according to any one of (1) to (12), wherein the resin portion has a first resin portion in which a part of the first portion and the sensor portion are embedded, and a second resin portion in which another part of the first portion is embedded, the second resin portion protrudes from the first resin portion to the other side in the second direction, and the dimension of the second resin portion in the first direction is smaller than the dimension of the first resin portion in the first direction.

[0093] 10, 210... Motor control device, 11... Housing, 12d... Housing hole, 24... Power module, 30, 230... Current sensor, 31, 231... Resin part, 31a... Opposing surface, 32... First resin part, 32c... Stepped surface, 33... Sensor fastening part, 33a... Through hole, 34... Substrate holding part, 34a... Holding hole, 37... Second resin part, 40... Bus bar, 41... First part, 41b...First protrusion, 43...Second part, 43b...Second protrusion, 43c...Hole, 45...Sensor part, 47...Terminal part, 50...Control board, 51...Board hole, 52...Through hole, 61...First fastening member, 62...Second fastening member, 63...Third fastening member, 70...Motor part, 71...Leader wire, 239...Protrusion, D1...First direction, D2...Second direction, D3...Third direction

Claims

1. A motor control device for supplying current to a motor section, comprising: a power module that generates the current supplied to the motor section; a current sensor positioned on one side of the power module in a first direction; and a housing that houses the power module and the current sensor, respectively, wherein the current sensor comprises: a resin part made of resin; a busbar, partly embedded in the resin part, that electrically connects the power module and the lead wires of the motor section; and a sensor part, embedded in the resin part, that detects the current flowing through the busbar, wherein the busbar comprises: a first portion extending in a second direction intersecting the first direction and passing through a housing hole that penetrates the housing in the second direction; and a second portion extending from one end of the first portion in the second direction to the other side in the first direction, wherein the second portion is fastened to the power module; the first portion has a first projection that protrudes from the resin part to the other side in the second direction, the first projection is located outside the housing and is fastened to the lead wires. A motor control device wherein the resin portion has a sensor fastening portion that is fastened to the housing, and the sensor fastening portion has a through hole that penetrates the sensor fastening portion in the second direction, and through which a first fastening member that fastens the sensor fastening portion and the housing passes in the second direction.

2. The motor control device according to claim 1, wherein the second portion has a second projection that protrudes from the resin portion to the other side in the first direction, and the second projection has a hole that penetrates the second projection in the second direction and through which a second fastening member that fastens the second projection and the power module passes in the second direction.

3. The motor control device according to claim 1, wherein the resin portion is passed through the housing hole in the second direction, and the other end of the resin portion in the second direction is located on the other side of the housing hole in the second direction.

4. The motor control device according to claim 1, comprising a control board positioned on one side of the current sensor in the second direction, wherein the current sensor has a terminal portion electrically connected to the sensor portion and protruding from the resin portion in one side of the second direction, and the control board has a through hole through which the terminal portion passes in the second direction.

5. The motor control device according to claim 4, wherein the terminal portion is press-fitted into the through-hole.

6. The motor control device according to claim 4, wherein the resin portion has a substrate holding portion that supports the control substrate from the other side in the second direction.

7. The motor control device according to claim 6, wherein the substrate holding portion is provided with a retaining hole recessed on the other side in the second direction, the control board is provided with a substrate hole that penetrates the control board in the second direction, and the control board is fixed to the substrate holding portion by a third fastening member that passes through the substrate hole in the second direction and is tightened into the retaining hole.

8. The motor control device according to any one of claims 1 to 7, wherein the resin part has an opposing surface facing one side in the first direction, and the opposing surface faces the inner surface of the housing at a distance from it.

9. The motor control device according to any one of claims 1 to 7, wherein the resin portion faces one side in the first direction and has a facing surface that faces the inner surface of the housing, and the facing surface is provided with a projection that protrudes to one side in the first direction and extends in the second direction.

10. The motor control device according to claim 9, wherein a portion of the protruding portion is in contact with the inner surface of the housing.

11. The motor control device according to claim 9, wherein one end of the protruding portion in the first direction is located on one side in the first direction as it moves toward one side in the second direction.

12. The motor control device according to claim 9, wherein the opposing surface has a stepped surface facing the other side of the second direction, and when viewed from a third direction intersecting both the first and second directions, the end of the protrusion on one side of the first direction is a straight line passing through the side of the stepped surface on one side of the first direction.

13. The motor control device according to any one of claims 1 to 7, wherein the resin portion has a first resin portion in which a part of the first portion and the sensor portion are embedded, and a second resin portion in which another part of the first portion is embedded, the second resin portion protrudes from the first resin portion to the other side in the second direction, and the dimension of the second resin portion in the first direction is smaller than the dimension of the first resin portion in the first direction.

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