FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]
ELECTRIC MOTOR CONTROL DEVICE
MITSUBISHI ELECTRIC CORPORATION, A CORPORATION ORGANISED AND
EXISTING UNDER THE LAWS OF JAPAN, WHOSE ADDRESS IS 7-3,
MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 100-8310, JAPAN
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE
INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.
2
[DESCRIPTION]
[Technical Field]
[0001]
The present disclosure relates to an electric motor control device.
[Background Art]5
[0002]
Conventionally, an electromechanical integrated control device is known. The
electromechanical integrated control device includes an electric motor and a controller to
control the electric motor. The controller has a power circuit that supplies electric
power to the electric motor, a control circuit, and a substrate to which electronic10
components are mounted on. Terminals of wiring that extends from the electric motor
and a power supply or the like are connected to the substrate. In Patent Document 1, a
structure in which terminals of the electric motor are connected to the substrate is
disclosed.
[Citation List]15
[Patent Document]
[0003]
Patent Document 1: Japanese Patent No. 6500952
[Summary of Invention]
[PROBLEM TO BE SOLVED BY THE INVENTION]20
[0004]
Busbars however, are mounted to the substrate in the device disclosed in Patent
Document 1. When the terminals of the electric motor are connected to the busbars by
press-fitting, stresses are generated in the substrate, and a problem of damage being
caused to electronic components mounted on the substrate exists.25
3
[0005]
The present disclosure has been made in order to address the problem above,
and an object is to provide an electric motor control device capable of reducing stresses
generated in a substrate wiring and the electronic components, when terminals of the
electric motor and the substrate are being connected.5
[MEANS TO SOLVE THE PROBLEM]
[0006]
An electric motor control device includes an electric motor and a controller.
The electric motor has a mechanical part and electric motor terminals that supply electric
power to the mechanical part. The controller that controls a drive of the electric motor,10
the controller having: a unit case, a substrate that is located between the electric motor
and the unit case, wherein the substrate has an electric circuit, a connector that receives
electrical power and a signal of the input from an outside of the electric motor control
device, relay components that have relay terminals that connect the electric motor
terminals and the electric circuit, and that transmit an electrical connection between the15
electric motor and the substrate. The unit case fixes the substrate, the connector, and the
relay components. The motor terminals extend towards the controller from the electric
motor. The motor terminals are connected to the relay terminals of the relay
components. The relay terminals are electrically connected to the electric circuit.
[EFFECTS OF THE INVENTION]20
[0007]
According to an electric motor control device of the present disclosure, it is
possible to reduce stresses that are generated in a substrate, as well as the stresses that are
generated in electronic components that are provided on the substrate.
25
4
[Brief Description of Drawings]
[0008]
FIG. 1 is a cross-sectional view that shows a configuration of an electric motor control
device according to a first embodiment.
FIG. 2 is an exploded perspective view that shows the electric motor control device5
according to the first embodiment.
FIG. 3 is a schematic perspective view that shows a connection portion of motor
terminals and relay components of the electric motor control device according to the first
embodiment.
FIG. 4 is a cross-sectional view taken along a cross-section line X-X shown in FIG. 3.10
FIG. 5 is a schematic perspective view that shows a condition of a state of the motor
terminals prior to connecting the motor terminals to the relay terminals, and is a view that
abbreviates a socket and a unit case that are shown in FIG. 3.
FIG. 6 is a perspective view that shows the relay components that the electric motor
control device is configured from, according to the first embodiment.15
FIG. 7 is a cross-sectional view that shows a configuration of the electric motor control
device according to a second embodiment.
FIG. 8 is a cross-sectional view that shows a configuration of the electric motor control
device according to a third embodiment.
FIG. 9 is a cross-sectional view that shows a configuration of the electric motor control20
device according to a fourth embodiment.
FIG. 10 is a cross-sectional view taken along the cross-section line X-X shown in FIG. 3,
and is a view that schematically shows a configuration of the electric motor control
device according to a fifth embodiment.
FIG. 11 is a plan view that shows integral type relay components in a state where the25
5
integrated type relay components are assembled to a unit case where the relay
components and a connector are integrally formed, and is a view that shows a
configuration of the electric motor control device according to a sixth embodiment.
FIG. 12 is a perspective view that shows the integrated type relay components where the
relay components and the connector are integrally formed, and is a view that shows a5
configuration of the electric motor control device according to the sixth embodiment.
[Description of Embodiments]
[0009]
Hereinafter, an embodiment of an electric motor control device is explained with
reference to FIG. 1 to FIG. 12. Similar reference signs are affixed to configuration10
portions that are identical or similar to one another in FIG. 1 to FIG. 12.
The electric motor control device according to a present embodiment is an
electromechanical integrated type control device of an integrated mechanical part of the
electric motor and a controller that controls the electric motor.
[0010]15
In an explanation of the electric motor control device according to the present
embodiment, an axial direction that a motor 10 which configures the electric motor
control device is simply referred to as the “axial direction”. A radial direction of the
motor 10 is simply referred to as the “radial direction”.
[0011]20
First Embodiment
An electric motor control device 1 according to a first embodiment is explained
with reference to FIG. 1 to FIG. 6. For example, the electric motor control device 1
according to the first embodiment is used in an electric power steering device so as to
assist a vehicle operator in steering operations. An electric motor control device 125
6
outputs steering assist torque to the electric power steering device. The electric power
steering device is driven based on the steering assist torque which is input from the
electric motor control device 1.
[0012]
5
An overall configuration of the electric motor control device 1 is explained with
reference to FIG. 1 and FIG. 2. The electric motor control device 1 includes the motor
10 (mechanical part) and a drive controller 20 (controller). The electric motor control
device 1 has a structure where the motor 10 and the drive controller 20 are integrally
formed.10
[0013]

The motor 10 functions as an electric motor. In other words, the motor 10
functions as a rotating electrical machine. The motor 10 is a three phase brushless
motor. The motor 10 includes a motor case 11, a plurality of stators 12, windings 13, a15
rotor 14, a shaft 15, an annular connection ring 16, and motor terminals 18 (electric
motor terminals). The plurality of stators 12, the windings 13, the rotor 14, a portion of
the shaft 15, the annular connection ring 16 and the motor terminals 18 are housed inside
of the motor case 11. The plurality of stators 12, the windings 13, the rotor 14 and the
shaft 15 configure the mechanical part of the electric motor.20
[0014]

The motor case 11 is configured of metallic parts. A material that configures
the motor case 11 considers heat dissipatability of the heat that is generated from the
motor 10, and machinability of the motor case 11. As an example of the material that25
7
configures the motor case 11, iron, and aluminum or the like are preferable.
The motor case 11 has through holes 11a. The through holes 11a are provided
on a grounding portion of the drive controller 1. As is to be mentioned later on, screws
50 are inserted through the through holes 11a.
[0015]5

The plurality of stators 12 are fixed to an inner wall of the motor case 11.
The plurality of stators 12 are disposed in a circular fashion so as to surround the
rotor 14. Each of the plurality of stators 12 faces the rotor 14 through an opening. The
windings 13 are wound around each of the plurality of stators 12. Although details are10
not shown in FIG. 1, a U phase stator 12U, a V phase stator 12V, and a W phase stator
12W that correspond to a U phase, a V phase, and a W phase of a three phase alternating
current are disposed in the inner wall of the motor case 11. In the explanation below,
there are cases where the “stators 12 of the three phases” are simply referred to as
“stators 12”.15
[0016]

The windings 13 are wound around each of the U phase stator 12U, the V phase
stator 12V, and the W phase stator 12W. Specifically, a U phase winding 13U is wound
around the U phase stator 12U. A V phase winding 13V is wound around the V phase20
stator 12V. A W phase winding 13W is wound around the W phase stator 12W. In the
explanation below, there are cases where the “windings 13 of the three phases” are
simply referred to as “windings 13”.
[0017]
25
8
An annular connection ring 16 has a circular shape. Terminal portions 13T of
each of the U phase winding 13U, the V phase winding 13V, and the W phase winding
13W are each disposed in the vicinity of the annular connection ring 16. Specifically, a
terminal portion 13TU of the U phase winding 13U, a terminal portion 13TV of the V
phase winding 13V, and a terminal portion 13TW of the W phase winding 13W are5
connected to the annular connection ring 16.
[0018]

The motor terminals 18 are for transmitting electric power that drives the motor
10 to the windings 13.10
The motor terminals 18 are electrically connected to each of the windings 13 of
the three phases, in other words, the U phase winding 13U, the V phase winding 13V and
the W phase winding 13W. Specifically, a U phase motor terminal 18U is connected to
the U phase winding 13U. A V phase motor terminal 18V is connected to the V phase
winding 13V. A W phase motor terminal 18W is connected to the W phase winding15
13W. In the explanation below, there are cases where the “motor terminals 18 of the
three phases” are simply referred to as “motor terminals 18”.
The motor terminals 18 extend from the motor 10 towards the drive controller
20.
[0019]20

The rotor 14 is fixed so as to surround the shaft 15 on the inside of the motor
case 11. The rotor 14 is configured of permanent magnets.
[0020]
9

The shaft 15 is a rod shaped part. Well-known metallic materials are used as a
material of the shaft 15. The center of the shaft 15 and the center of the rotor 14 are
concentric, as seen from an axial direction. The shaft 15 extends from the motor 10
towards the drive controller 20, so as to extend in the axial direction. The shaft 15 has a5
first shaft part 15A and a second shaft part 15B. Out of parts of the shaft 15, the first
shaft part 15A is the part that is housed inside of the motor case 11. Out of parts of the
shaft 15, the second shaft part 15B is the part that protrudes from the motor case 11
towards the drive controller 20.
[0021]10
The first shaft part 15A is supported by a first bearing 40 provided inside of the
motor case 11.
The second shaft part 15B is supported by a second bearing 41 that is provided
in a unit case 27, which is to be mentioned later on. That is, the shaft 15 is rotatably
supported by the first bearing 40 and the second bearing 41. As such, it is possible for15
the shaft 15 and the rotor 14 to rotate. In other words, the second shaft part 15B is an
output shaft of the motor 10.
[0022]
20
The drive controller 20 functions as a controller that controls a drive of the
motor 10.
The drive controller 20 mainly includes a substrate 21, a connector 25, the unit
case 27, and relay components 60. The substrate 21 and the relay components 60 are
each fixed to the unit case 27 in the drive controller 20.25
10
The drive controller 20 is connected to the motor 10 previously mentioned, in
the axial direction. The shaft 15 penetrates the drive controller 20 in a central part 20C
of the drive controller 20.
[0023]
5
The substrate 21 is located between the motor 10 and the unit case 27.
An example of the substrate 21 is a well-known circuit board having a printed
substrate. The type of the substrate 21 is not limited in the first embodiment.
The substrate 21 has a vertical surface with respect to the axial direction. In
the explanation below, regarding surfaces of the substrate 21, a surface of the substrate10
21 that faces the motor 10 (motor facing surface) is referred to as a “first surface 21a”.
The surface of the substrate 21 that faces the drive controller 20 (drive controller facing
surface) is referred to as a “second surface 21b”.
[0024]
The substrate 21 is fixed to substrate support parts 27c of the unit case 27, to be15
mentioned later on, by screws 51. It is preferable to fix the substrate 21 and the
substrate support parts 27c at multiple locations around the substrate 21. In such a case,
it is possible to prevent hovering away of the substrate 21 from the unit case 27 that
results during assembly of the substrate 21 to the unit case 27.
A CPU 36 (Central Processing Unit) and capacitors 35 are mounted on the20
second surface 21b.
[0025]
Connection terminals that are electrically connected to the substrate 21 are
formed on the second surface 21b. Specifically, connection terminals that are connected
to relay connection parts 61c (substrate connection part) of the relay terminals 61 to be25
11
mentioned later on, connection terminals that are connected to connector connection
parts 25b (substrate connection part) of the connector 25 to be mentioned later on, and
connection terminals that are connected to sensor connection parts 26a (substrate
connection part) of a rotation sensor 26 to be mentioned later on are formed on the
second surface 21b.5
[0026]
Substrate through holes 21d through which the motor terminals 18 are inserted
through are formed in the substrate 21. The substrate through holes 21d are formed in
locations that correspond to the motor terminals 18. Electronic components are
disposed in a region 21I that is located in the inside radial direction more than the three10
substrate through holes 21d.
Three holes are formed in a location that is on an outside radial direction of each
of the substrate through holes 21d. The three holes are disposed along the longitudinal
direction of the substrate through holes 21d, and are formed adjacent to one of the
substrate through holes 21d. The relay connection parts 61c which are shown in FIG. 515
to be mentioned later on, penetrate each of the three holes, and are connected to the
substrate 21 by soldering
[0027]

The unit case 27 includes the substrate support parts 27c, a holding part 27S, the20
rotation sensor 26, and a rotation sensor rotor 19. The unit case 27 fixes the substrate
21, the connector 25, and the relay components 60.
[0028]
The unit case 27 is configured from metallic parts. A material that configures
the unit case 27 considers heat dissipatability of the heat that is generated from the25
12
electric motor control device 1, and machinability of the unit case 27. As a material that
configures the unit case 27, for example, aluminum or the like are preferable.
The substrate support parts 27c are parts to which the screws 51 that are inserted
through the through holes of the substrate 21 are screwed into. The substrate 21 and the
unit case 27 are fixed by the screws 51 in the substrate support parts 27c.5
[0029]
The holding part 27S is a part that holds the rotation sensor 26 and the rotation
sensor rotor 19. The rotation sensor 26 is fixed to the unit case 27 by the holding part
27S.
For example, the rotation sensor 26 is a resolver. A resolver coil is housed10
inside the rotation sensor 26. The rotation sensor 26 has a sensor connection part 26a.
The sensor connection part 26a is a terminal that is connected to the substrate 21 by
soldering or the like.
[0030]
The rotation sensor rotor 19 is installed on the second shaft part 15B that is15
supported by the second bearing 41. The rotation sensor rotor 19 faces the rotation
sensor 26. When the motor 10 is driven, the shaft 15 rotates along, and the rotation
sensor rotor 19 rotates with the second shaft part 15B. As such, the rotation sensor 26
detects the rotation angle of the shaft 15.
[0031]20
The unit case 27 has a hole 27H provided at a location corresponding to the
central part 20C of the drive controller 20. It is possible for the second shaft part 15B of
the shaft 15 to penetrate through the hole 27H. A connector fixing part 27E is formed
on a portion of an outer circumference of the unit case 27. The connector fixing part
27E is a partly cut off portion of the part of the outer circumference of the unit case 27.25
13
The connector 25 is installed onto the connector fixing part 27E.
[0032]
Female thread parts 27a are formed on an outer periphery 27F of the unit case 27.
The screws 50 that are inserted through the through holes 11a of the motor case 11 are
screwed into the female thread parts 27a. By screwing the screws 50 into the female5
thread parts 27a, the motor case 11 is fastened to the unit case 27, and is fixed to the unit
case 27.
[0033]
A profile of the drive controller 20 is formed by combining a profile of a
metallic unit case 27 and a profile of a resin part 25c of the connector 25. The unit case10
27 has a function of covering the drive controller 20. It is possible to refer to the unit
case 27 as a “housing”.
[0034]
In the unit case 27, portions other than the portions which have the substrate
support parts 27c formed have a shorter height than a height of the substrate support parts15
27c in the axial direction. For such a reason, a gap 27e is formed between a top surface
27U of the unit case 27, and the second surface 21b of the substrate 21. The unit case
27 has socket seating surfaces 27h and socket press-fit holes 27g that are mentioned later
on. The socket seating surfaces 27h are located on a lower surface of a recess part 27B
that is formed on the top surface 27U. The socket press-fit holes 27g are holes that are20
provided in the socket seating surfaces 27h.
[0035]
A heat dissipating part 37 having a high thermal conductivity is disposed in the
gap 27e. The heat dissipating part 37 dissipates heat that the CPU 36 generates to the
unit case 27. Recessed parts 27f are formed on locations of the top surface 27U that25
14
corresponds to the capacitors 35 mounted on the second surface 21b. The heat
dissipating part 37 is disposed in the gap 27e, and it is possible to dissipate the heat
generated from the capacitors 35 to the unit case 27.
[0036]
5
The relay components 60 are motor connection parts that connect the motor
terminals 18 and the substrate 21.
In other words, the relay components 60 are relay components that relay an
electrical connection between the motor 10 and the drive controller 20.
[0037]10
The relay components 60 are configured from the relay terminals 61 and sockets
62. The sockets 62 are resin parts. The relay terminals 61 are connected to the motor
terminals 18 previously mentioned. As is mentioned later on, the relay terminals 61
have the relay connection parts 61c. The relay terminals 61 connect the motor terminals
18 and a circuit board of substrate 21.15
[0038]
The sockets 62 are fixed at a location closer to the motor 10 than to the substrate
21.
As a modification example, it is possible to fix the sockets 62 to the unit case 27
in a location on an opposite side of the motor 10 with respect to the substrate 21.20
[0039]
The relay terminals 61 are electrically connected to each of the three phase
motor terminals 18, in other words, the U phase motor terminal 18U, the V phase motor
terminal 18V, and the W phase motor terminal 18W. Specifically, the U phase motor
terminal 18U is connected to a U phase relay terminal 61U. The V phase motor25
15
terminal 18V is connected to a V phase relay terminal 61V. The W phase motor
terminal 18W is connected to a W phase relay terminal 61W. In the explanation below,
there is a case where the relay terminals 61 of the three phases are simply referred to as
the “relay terminals 61”.
[0040]5
There is a case where the relay components that have the U phase relay terminal
61U are referred to as the “U phase relay components”. There is a case where the relay
components that have the V phase relay terminal 61V are referred to as the “V phase
relay components”. There is a case where the relay components that have the W phase
relay terminal 61W are referred to as the “W phase relay components”. In the10
explanation below, there is a case where the relay components 60 of the three phases are
simply referred to as the “relay components 60”.
[0041]
The motor terminals 18 that are inserted through the substrate through holes 21d
are connected to the relay terminals 61 by press-fitting.15
The relay terminals 61 are integrally formed with the sockets 62. The sockets
62 are fixed to the unit case 27. The relay terminals 61 are electrically connected to the
substrate 21 by soldering or the like.
In other words, the motor terminals 18 are connected to the substrate 21 through
the relay terminals 61 of the relay components 60. As such, the drive controller 20 is20
electrically connected to the motor 10 through the relay components 60.
[0042]

The connector 25 is a part that is exposed to the outside of the electric motor
control device 1.25
16
The connector 25 receives electric power and a signal that are input from the
outside of the electric motor control device 1.
The connector 25 has power terminals 25a (power terminals), signal terminals
that are not shown, the connector connection parts 25b, and the resin part 25c. The
power terminals 25a and the signal terminals are housed inside of the connector 25.5
The power terminals 25a are terminals that are connected to a battery installed in a
vehicle. The signal terminals are terminals that are connected to various information
detecting sensors of the electric motor control device 1.
The connector 25 is fixed to the unit case 27 by screws 52. The connector
connection parts 25b of the connector 25 are electrically connected to the substrate 21 by10
soldering or the like.
[0043]
A manufacturing method of the previously mentioned electric motor control
device 1 is explained below.
First, the connector 25 and the relay components 60 are assembled to the unit15
case 27. After that, the substrate 21 is assembled to the unit case 27. As such, the
drive controller 20 is obtained. Next the drive controller 20 and the motor 10 are
assembled to one another. At such time, the motor terminals 18 are connected to the
substrate 21 through the relay terminals 61.
[0044]20

Next, terminal connection structures in the electric motor control device 1 are
explained by referencing FIG. 3 to FIG. 6. In such terminal connection structures, the
motor terminals 18 pulled out from the windings 13 are connected to the relay terminals
61.25
17
In FIG. 3 to FIG. 5, a part where the substrate 21, the motor terminals 18, the
relay terminals 61, and the sockets 62 are provided is shown, and an overall shape of the
substrate 21 and the unit case 27 is simplified.
[0045]
As shown in FIG. 3 to FIG. 6, the relay components 60 are configured from the5
relay terminals 61 and the sockets 62. The relay terminals 61 and the sockets 62 are
integrally formed. As examples of methods for integrally forming the relay terminals
61 and the sockets 62, an outsert molding method or an insert molding method may be
mentioned. By press-fitting the relay components 60 into the unit case 27, the relay
components 60 and the unit case 27 are assembled.10
[0046]
As shown in FIG. 4 and FIG. 6, the sockets 62 for example, have cylindrical
parts 62a and a plurality of ribs 62b. The sockets 62 have facing surfaces 62f that face
socket seating surfaces 27h. The cylindrical parts 62a protrude from the facing surface
62f. The plurality of ribs 62b are provided around the cylindrical parts 62a. The ribs15
62b protrude from the surface of the cylindrical parts 62a towards an outside radial
direction of the cylindrical parts 62a. As shown in an example of FIG. 6, the ribs 62b
extend along a direction in which the cylindrical parts 62a protrude from the facing
surface 62f.
[0047]20
In the example shown in FIG. 6, although two of the ribs 62b are formed around
the cylindrical parts 62a, a number of the ribs 62b is not limited thereto. It is possible to
have a plurality of ribs 62b provided around the cylindrical parts 62a at equal intervals.
A shape of the ribs 62b is not limited to the shape shown in in FIG. 6. For
example, the ribs 62b may be a plurality of dots (dotted parts) that protrude from the25
18
surface of the cylindrical parts 62a. The ribs 62b may be an annularly shaped ring
(annular part) that is concentric with the cylindrical parts 62a, along with protruding from
the surface of the cylindrical parts 62a. The ribs 62b may extend along a direction that
intersects a direction in which the cylindrical parts 62a extends from the facing surface
62f. The ribs 62b may be formed in a spiral shape on the surface of the cylindrical parts5
62a. In other words, the ribs 62b may have a male thread shape that is formed on the
surface of the cylindrical parts 62a.
If the shapes of the cylindrical parts 62a and the ribs 62b are elastically
deformable when the sockets 62 are press-fitted into the socket press-fit holes 27g, the
number of the ribs 62b, the disposition of the ribs 62b, and the shapes of the ribs 62b are10
not limited.
[0048]
As shown in FIG. 4, the unit case 27 has the socket press-fit holes 27g.
Although in FIG. 4 one socket press-fit holes 27g are shown, the socket press-fit holes
27g are provided in three locations in the unit case 27, corresponding to the three phases15
of the relay components 60. In other words, U phase socket press-fit holes 27g, V phase
socket press-fit holes 27g, and W phase socket press-fit holes 27g are provided in the unit
case 27.
[0049]
A radius A of the socket press-fit holes 27g is larger than a radius B (A>B) of the20
cylindrical parts 62a of the sockets 62. The radius A of the socket press-fit holes 27g is
smaller than a width C (C>A) that includes the cylindrical parts 62a of the sockets 62 and
the ribs 62b. The phrase “a width C that includes the cylindrical parts 62a of the
sockets 62 and the ribs 62b” means a width in the radial direction of the cylindrical parts
62a, in a cross-section of the cylindrical parts 62a that is parallel to the facing surface 62f.25
19
Two points that govern a distance of the width C may be the distance between two end
surfaces of the ribs 62b, or the distance between one end surface of the ribs 62b and the
surface of the cylindrical parts 62a.
[0050]
The relay components 60 is press-fitted into the unit case 27 having the5
previously mentioned shape. When press-fitting the relay components 60 into the unit
case 27, first, the cylindrical parts 62a in which the ribs 62b are formed are made to face
the socket press-fit holes 27g. The cylindrical parts 62a and the ribs 62b are inserted
into the socket press-fit holes 27g. Since the radius A is smaller than the width C, the
ribs 62b are pressed in towards an inside radial direction of the socket press-fit holes 27g10
by an inner wall of the socket press-fit holes 27g. The relay components 60 are press-fit
into the unit case 27 as the cylindrical parts 62a and the ribs 62b elastically deform due to
a pressing force applied to the ribs 62b, or due to the pressing force applied to both the
cylindrical parts 62a and the ribs 62b. The relay components 60 are press-fitted into the
unit case 27 in the axial direction at least until a portion of the facing surface 62f of the15
sockets 62 contacts the socket seating surfaces 27h of the unit case 27. The U phase, V
phase, and W phase of the relay components 60 are each press-fitted into the socket
press-fit holes 27g of the U phase, the V phase, and the W phase.
[0051]
“Fixing the sockets 62 by press-fitting into the unit case 27” means to have the20
cylindrical parts 62a of the sockets 62 and the ribs 62b elastically deform on an inside of
the socket press-fit holes 27g. The cylindrical parts 62a are fixed in the socket press-fit
holes 27g due to the restoring force of the cylindrical parts 62a and the ribs 62b.
[0052]
When it is possible to press-fit the sockets 62 into the socket press-fit holes 27g25
20
of the unit case 27, the shape of the sockets 62 is not limited to the shape shown in the
previously mentioned embodiment.
As a modification example, an adhesive may be applied between the relay
components 60 and the socket seating surfaces 27h, therefore fixing the relay
components 60 to the unit case 27. As such, it is possible to fix the relay components5
60 and the unit case 27 by an adhesion force of the adhesive, and not only fixing by the
press-fitting of the relay components 60 and the unit case 27 previously mentioned. As
a type of the adhesive, a well-known adhesive material is used.
[0053]
As a modification example, the relay components 60 and the unit case 27 do not10
need to be fixed by press-fitting. In such a case, the relay components 60 and the unit
case 27 are fixed due to the adhesion force of the adhesive. Even in such a case, a
sufficient fixing force to fix the relay components 60 and the unit case 27 is obtainable.
[0054]
The relay terminals 61 are formed of a bent sheet metal such as copper or the15
like.
As shown in FIG. 5, flat surface parts 61a of the relay terminals 61 are disposed
so vertically with respect to the axial direction. The flat surface parts 61a have through
holes 61b in two locations so as to connect the motor terminals 18 and the relay terminals
61.20
[0055]
A tip of tips 18a of the motor terminals 18 has a shape where the tip of the tips
18a of the motor terminals 18 is split into two. In other words, the tips 18a of the motor
terminals 18 have a forked shape. When the tips 18a of the motor terminals 18 are
inserted through the through holes 61b of the relay terminals 61 by press-fitting, the tips25
21
18a of the motor terminals 18 expand in the through holes 61b, and it is possible to
elastically connect the tips 18a and the through holes 61b. From the above, the motor
terminals 18 and the relay terminals 61 are electrically connected.
[0056]
The shapes of the motor terminals 18 and the relay terminals 61 each are not5
limited to the shapes of the motor terminals 18 and the relay terminals 61 shown in the
previously mentioned embodiments, when it is possible to electrically connect the motor
terminals 18 and the relay terminals 61 by press-fitting the motor terminals 18 with
respect to the relay terminals 61.
[0057]10
The relay connection parts 61c of the relay terminals 61 extend in the vertical
direction with respect to the flat surface parts 61a in which the motor terminals 18 are
inserted through. In other words, the relay connection parts 61c and the flat surface
parts 61a form an L shape. The relay connection parts 61c have a shape where the relay
terminals 61 are split into three parts. In other words, the relay connection parts 61c15
have a three pronged fork shape. In other words, the relay connection parts 61c have
three terminals. The relay connection parts 61c are connected to the substrate 21 by
soldering or the like. The terminals of the relay connection parts 61c are not limited to
three. The number of terminals of the relay connection parts 61c may be two, or may be
greater than or equal to four.20
[0058]
As shown in FIG. 5, the relay connection parts 61c go through the substrate
through holes 21d. It is preferable that the relay connection parts 61c which go through
the substrate through holes 21d be disposed on the outside radial direction of the
substrate 21. In such a case, it is possible to dispose the electronic components in the25
22
region 21I of the substrate 21 that is located in the inside radial direction more than the
substrate through holes 21d.
[0059]
In the first embodiment having the configurations mentioned above, each of the
substrate 21 and the relay components 60 is fixed to the unit case 27. According to such5
configurations, the motor terminals 18 are not directly connected to the substrate 21.
The motor terminals 18 are electrically connected to the substrate 21 through the relay
components 60. Therefore, it is possible reduce stresses that are generated in the
substrate 21 which result from the motor terminals being directly connected to the
substrate.10
[0060]
By disposing the relay connection parts 61c on the outside radial direction of the
substrate through holes 21d of the substrate 21, it becomes easier to dispose electronic
components in the region 21I that is located in the inside radial direction of the substrate
through holes 21d in the substrate 21. By disposing the electronic components in the15
region 21I, even in a case where stresses are generated in the substrate 21 and the
connection terminals, it is possible to reduce a transmission of stress from the substrate
through holes 21d to the electronic components.
[0061]
The relay connection parts 61c of the relay terminals 61 have a plurality of20
divided terminals. In the first embodiment, the relay connection parts 61c have three
terminals. In a condition of constant cross-sectional areas, it is possible to reduce a
rigidity of the relay connection parts 61c in the case where the relay connection parts 61c
have a plurality of terminals, when comparing a case where the relay connection parts
61c have one terminal to a case where the relay connection parts 61c have a plurality of25
23
terminals. For such reason, in a case where stresses are generated in the plurality of
terminals of the relay connection parts 61c, it is possible to reduce the transmission of
stress to the substrate 21. Also, when the relay connection parts 61c have a plurality of
terminals, it is possible to continuously maintain the electrical connection even in a case
where one of the plurality of terminals is ruptured.5
[0062]
In the first embodiment, the connection terminals to which the relay connection
parts 61c are connected to, the connection terminals to which the connector connection
parts 25b are connected to, and the connection terminals to which the sensor connection
part 26a is connected to, are formed on the second surface 21b of the substrate 21. In10
other words, the aforementioned connection terminals are not formed on the first surface
21a.
[0063]
For such a reason, it is possible to connect the sensor connection part 26a, the
connector connection parts 25b, and the relay connection parts 61c to the second surface15
21b of the substrate 21 only by soldering or the like. It is possible to conduct the
aforementioned connection while the substrate 21 is fixed, without the need to invert the
first surface 21a and the second surface 21b. It is possible to collectively connect the
sensor connection part 26a, the connector connection parts 25b, and the relay connection
parts 61c to the substrate 21 in a single connection process, and it is possible to20
efficiently produce the electric motor control device 1.
[0064]
Next, each of a plurality of embodiments that differ from the first embodiment
mentioned above is explained.
In the explanation below, components similar to components of the first25
24
embodiment have the same reference signs affixed thereto, and explanations thereof are
omitted.
[0065]
Second Embodiment
Terminal connection structures of an electric motor control device according to a5
second embodiment are explained with reference to FIG. 7.
[0066]
The second embodiment and the first embodiment are similar with regards to a
method of fixing the relay components 60 to a unit case. The second embodiment and
the first embodiment differ with regards to a shape and configuration of a substrate, along10
with a structure of fixing the unit case to the substrate. Points of difference between the
first embodiment and the second embodiment are emphasized in the explanation below.
[0067]
The substrate included in an electric motor control device 2 according to the
second embodiment differs from the substrate 21 mentioned above in that the substrate is15
configured of a plurality of substrates.
Specifically, the electric motor control device 2 includes a power substrate 22
and a control substrate 23. The power substrate 22 has an inverter circuit that supplies
electric power to the motor 10. The control substrate 23 has a control circuit that
controls the drive of the motor 10. To configure each of the inverter circuit and the20
control circuit, well-known circuit configurations may be used.
A unit case 28 corresponds to the unit case 27 explained in the first embodiment.
[0068]
The power substrate 22 and the control substrate 23 are electrically connected to
one another by connection terminals 38 or the like. For example, the power substrate 2225
25
and the unit case 28 are disposed so as to face one another. The control substrate 23 and
the motor 10 are disposed so as to face one another. The power substrate 22 and the
control substrate 23 are disposed vertically with respect to the motor terminals 18. Each
of the power substrate 22 and the control substrate 23 are fixed to the unit case 28 by
screws 51.5
[0069]
It is also possible to change the dispositions of the power substrate 22 and the
control substrate 23. In other words, the power substrate 22 may be disposed so as to
face the motor 10. The control substrate 23 may be disposed so as to face the unit case
28.10
[0070]
The relay components 60 connected to the motor terminals 18 are disposed
between the power substrate 22 and the unit case 28. The relay connection parts 61c are
connected to the power substrate 22.
[0071]15
In a configuration of a single substrate that includes an overlap of the functions
of the power substrate 22 and the control substrate 23, a surface area of the substrate
becomes large, and a limit exists as to how much a profile size of the substrate may be
made smaller. In other words, to integrate the inverter circuit and the control circuit
onto a single substrate, the surface area of the substrate is increased.20
[0072]
With respect to the above, same or similar effects as the embodiment mentioned
above are obtainable according to the second embodiment. Since the power substrate
22 and the control substrate 23 each have differing functions, there is no need to integrate
the inverter circuit and the control circuit onto a single substrate. Therefore, it is25
26
possible to reduce the profile size of a single substrate, when compared to a configuration
where the inverter circuit and the control circuit are integrated onto a single substrate.
By disposing the power substrate 22 and the control substrate 23 so as to face one
another in a parallel fashion in the axial direction, it is possible to downsize the profile
size of the radial direction of the drive controller 20.5
[0073]
Third Embodiment
Terminal connection structures of an electric motor control device according to a
third embodiment are explained with reference to FIG. 8.
[0074]10
The third embodiment and the first embodiment are similar with regards to a
method of fixing relay components to a unit case. The third embodiment and the first
embodiment differ with regards to a disposition of the relay components and a substrate,
and shapes of sockets, relay terminals, the substrate, and the unit case. Points of
difference between the first embodiment and the third embodiment are emphasized in the15
explanation below.
[0075]
In an electric motor control device 3 according to the third embodiment, relay
components 65 correspond to the relay components 60 explained in the first embodiment.
A substrate 24 corresponds to the substrate 21 explained in the first embodiment. A unit20
case 29 corresponds to the unit case 27 explained in the first embodiment.
[0076]
The relay components 65 are disposed to an outside of the radial direction more
than an outer circumference of the substrate 24. The substrate 24 and the relay
components 65 are fixed to the unit case 29.25
27
The relay components 65 are configured of relay terminals 66 and sockets 67.
The relay terminals 66 correspond to the relay terminals 61 explained in the first
embodiment. The sockets 67 correspond to the sockets 62 explained in the first
embodiment. The connection structures of the motor terminals 18 and the relay
terminals 66 are similar to the connection structures of the motor terminals 18 and the5
relay terminals 66 in the first embodiment. Relay connection parts that connect the
substrate 24 and the relay terminals 66 are disposed to the inside radial direction more
than the motor terminals 18. The relay terminals 66 are connected to the substrate 24,
similarly to the relay connection parts 61c that are shown in FIG. 3 to FIG. 6.
[0077]10
The substrate 24 does not have substrate through holes through which the motor
terminals 18 are inserted through. The motor terminals 18 are not inserted through the
substrate 24.
[0078]
With respect to the above, same or similar effects as the embodiments mentioned15
above are obtainable according to the third embodiment. Since the motor terminals 18
are not inserted through the substrate 24, there is no need to form through holes in the
substrate 24. For such a reason, a region to which components of the substrate 24 are
mounted on increases.
[0079]20
Fourth Embodiment
Terminal connection structures of an electric motor control device according to a
fourth embodiment are explained with reference to FIG. 9.
[0080]
The fourth embodiment and the first embodiment are similar with regards to a25
28
method of fixing relay components to a unit case. The fourth embodiment and the fist
embodiment differ with regards to a disposition of the relay components, a substrate, and
a connector, and a shape of the unit case. Points of difference between the first
embodiment and the fourth embodiment are emphasized in the explanation below.
[0081]5
In an electric motor control device 4 according to the fourth embodiment, relay
components 75 correspond to the relay components 60 explained in the first embodiment.
A substrate 24 corresponds to the substrate 21 explained in the first embodiment. A unit
case 30 corresponds to the unit case 27 explained in the first embodiment. A connector
39 corresponds to the connector 25 explained in the first embodiment. Connector10
connection parts 39b corresponds to the connector connection parts 25b explained in the
first embodiment.
[0082]
The relay components 75 are disposed between the substrate 24 and the motor
10. Relay terminals 76 face the motor 10. The relay terminals 76 face a first surface15
24a of the substrate 24. The relay terminals 76 are connected to the substrate 24. The
terminal connection structures of the motor terminals 18 and the relay terminals 76 are
similar to the terminal connection structures of the first embodiment. The motor 10
faces relay connection parts that connect the substrate 24 and the relay terminals 76.
[0083]20
The substrate 24 has connection terminals that are connected to the relay
terminals 76. The substrate 24 does not have substrate through holes through which the
motor terminals 18 are inserted through. The motor terminals 18 are not inserted
through the substrate 24. The connector connection parts 39b of the connector 39 are
disposed between the substrate 24 and the motor 10. The connector connection parts25
29
39b face the first surface 24a of the substrate 24. The connector connection parts 39b
are connected to the substrate 24.
As a modified example of the fourth embodiment, the connector connection
parts 39b of the connector 39 are made to extend from a unit case 30, and the connector
connection parts 39b may be connected to the substrate 24.5
[0084]
With respect to the above, same or similar effects as the previously mentioned
embodiments are obtainable according to the fourth embodiment. Since the motor
terminals 18 are not inserted through the substrate 24, there is no need to form through
holes in the substrate 24. For such a reason, a region to which components of the10
substrate 24 are mounted on increases. Since the relay components 75 are not disposed
between the substrate 24 and the unit case 30, it is possible to downsize a structure of the
unit case 30.
[0085]
Fifth Embodiment15
Terminal connection structures of an electric motor control device according to a
fifth embodiment are explained with reference to FIG. 10. FIG. 10 shows a portion in
which the substrate 21, the motor terminals 18, the relay terminals 61, and the sockets 62
are provided. The shape of the substrate 21 and a shape of the unit case 27 are omitted
in FIG. 10.20
[0086]
The fifth embodiment and the first embodiment are similar with regards to
shapes and configurations of the unit case 27 and the relay components 60. The fifth
embodiment and the first embodiment differ with regards to a method of fixing the relay
components 60 to the unit case 27. Points of difference between the first embodiment25
30
and the fifth embodiment are emphasized in the explanation below.
[0087]
The fifth embodiment and the first embodiment are different. Points of
difference between the first embodiment and the fourth embodiment are emphasized in
the explanation below.5
As shown in FIG. 10, an adhesive 63 is first applied to the socket press-fit holes
27g and the socket seating surfaces 27h. The relay components 60 are press-inserted
into the axial direction with respect to the unit case 27. The relay components 60 are
fixed not only by press-fitting with respect to the unit case 27, but the relay components
60 are also fixed to the unit case 27 by the adhesive 63.10
[0088]
With respect to the above, same or similar effects as the previously mentioned
embodiments are obtainable according to the fifth embodiment. Further, it is possible to
further increase a strength of connection between the unit case 27 and the relay
components 60. Even in a case where the strength of connection decreases due to an15
operating environment of the electric motor control device 1, it is possible to insure the
strength of connection by the adhesive. For example, in a case where the temperature of
the operating environment of the electric motor control device 1 decreases, the strength
of connection in a press-fitted portion in between the unit case 27 and the relay
components 60 decreases due to a difference of a coefficient of linear expansion that is20
due to the difference of constituent materials of the sockets 62 and the unit case 27.
Even in such a case, it is possible to insure the strength of connection by using the
adhesive.
[0089]
Sixth Embodiment25
31
Terminal connection structures of an electric motor control device according to a
sixth embodiment are explained with reference to FIG. 11 and FIG. 12. Points of
difference between the first embodiment and the sixth embodiment are emphasized in the
explanation below.
[0090]5
An electric motor control device 6 according to the sixth embodiment includes
integrated type relay components 70 that have the relay components 60 and the connector
25 integrally formed. Similar to the first embodiment, the integrated type relay
components 70 have the relay terminals 61.
Although a unit case 31 in the electric motor control device 6 partially10
corresponds to the unit case 27 explained in the first embodiment, the unit case 31 has a
different configuration than the configuration of the unit case 27.
The integrated type relay components 70 for example, are fixed to the unit case
31 by screws 53.
[0091]15
As shown in FIG. 12, the integrated type relay components 70 have a connector
portion 70a and a socket portion 70b. The connector portion 70a and the socket portion
70b are integrally formed. Three relay terminals 61 are integrally formed into the
socket portion 70b. As examples of methods for integrally forming the relay terminals
61 and the socket portion 70b, an outsert molding method or an insert molding method20
may be mentioned. The socket portion 70b corresponds to the sockets 62 in the
previously mentioned embodiments.
[0092]
The socket portion 70b has through holes 71c through which screws are inserted.
The unit case 31 differs from the first embodiment in that the unit case 31 has female25
32
thread parts 31e that fix the integrated type relay components 70. The unit case 31 and
the integrated type relay components 70 are fixed to one another using a plurality of the
screws 53.
[0093]
It is possible to adopt any of the methods explained in the first or in the fifth5
embodiments previously mentioned as a fixing method of fixing the integrated type relay
components 70 to the unit case 31.
[0094]
Same or similar effects as the previously mentioned embodiments are obtainable
according to the sixth embodiment. Since the integrated type relay components 7010
where the connector and the sockets are integrally formed is used, it is possible to
simplify a process of assembling the integrated type relay components 70 onto the unit
case 31. The connector portion 70a and the socket portion 70b are fixed in several
places in the integrated type relay components 70. For such reason, the integrated type
relay components 70 is reliably fixed to the unit case 31.15
[0095]
The motor 10 that configures the electric motor control device 1 to 6 explained
in the first to sixth embodiments previously mentioned has a configuration where the
drive controller 20 is fixed to the output shaft of the motor 10. A structure where the
drive controller 20 is fixed to the motor 10 on an opposite side of the output shaft may be20
adopted as modified example. Even in such a structure, as a connection structure of the
motor terminals and the relay components, and a connection structure of the substrate
and the relay components, it is possible to adopt a connection structure similar to the
connection structure of the first to the sixth embodiments.
[Reference Signs List]25
33
[0096]
1, 2, 3, 4, 6 Electric Motor Control Device
10 Motor
18 Motor Terminals (Electric Motor Terminals)
20 Drive Control Device (Controller)5
21 Substrate
25 Connector
27 Unit Case
60 Relay Components
61 Relay Terminal10
62 Socket
34
WE CLAIM:
[Claim 1]
An electric motor control device, where the electric motor control device
comprises:
an electric motor having a mechanical part and electric motor terminals that5
supply electric power to the mechanical part; and
a controller that controls a drive of the electric motor, the controller having:
a unit case; a substrate having an electric circuit and is located between the
electric motor and the unit case; a connector that receives electric power and a signal
input from an outside of the electric motor control device;10
relay components that have relay terminals that connect the electric motor
terminals and the electric circuit, and that transmit an electrical connection between the
electric motor and the substrate, wherein,
the unit case fixes the substrate, the connector, and the relay components,
the motor terminals extend towards the controller from the electric motor,15
the motor terminals are connected to the relay terminals of the relay components,
and
the relay terminals are electrically connected to the electric circuit.
[Claim 2]
The electric motor control device according to claim 1, wherein:20
the substrate further comprises:
a power substrate that supplies electric power to the electric motor,
a control substrate that controls the drive of the electric motor, and
the relay terminals are connected to the power substrate.
25
35
[Claim 3]
The electric motor control device according to claim 1, wherein:
the relay components have sockets; and
the sockets are fixed to the unit case at a location closer to the electric motor
than to the substrate or in a location on an opposite side of the electric motor with respect5
to the substrate.
[Claim 4]
The electric motor control device according to any one of claims 1 to 3, wherein:
the relay components have sockets, and
the sockets are fixed to the unit case at least by one of:10
a restoring force that is generated in the sockets, and
an adhesion force of an adhesive material that is applied between the sockets and
the unit case.
[Claim 5]
The electric motor control device according to any one of claims 1 to 4, wherein:15
the relay components have sockets, and
the sockets and the connector are integrally formed.
[Claim 6]
The electric motor control device according to any one of claims 1 to 5, wherein:
the electric motor has an output shaft, and20
the controller is disposed on the output shaft of the electric motor.
[Claim 7]
The electric motor control device according to any one of claims 1 to 5, wherein:
the electric motor has an output shaft, and
25
36
the controller is disposed on an opposite side of the output shaft of the electric
motor.