WO2015122069A1 - 制御装置付き回転電機、電動パワーステアリング装置および制御装置付き回転電機の製造方法 - Google Patents
制御装置付き回転電機、電動パワーステアリング装置および制御装置付き回転電機の製造方法 Download PDFInfo
- Publication number
- WO2015122069A1 WO2015122069A1 PCT/JP2014/080456 JP2014080456W WO2015122069A1 WO 2015122069 A1 WO2015122069 A1 WO 2015122069A1 JP 2014080456 W JP2014080456 W JP 2014080456W WO 2015122069 A1 WO2015122069 A1 WO 2015122069A1
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- WIPO (PCT)
- Prior art keywords
- control device
- heat sink
- electrical machine
- rotating electrical
- rear side
- Prior art date
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/02—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for suppression of electromagnetic interference
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D5/00—Power-assisted or power-driven steering
- B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
- B62D5/0403—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by constructional features, e.g. common housing for motor and gear box
- B62D5/0406—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by constructional features, e.g. common housing for motor and gear box including housing for electronic control unit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D5/00—Power-assisted or power-driven steering
- B62D5/04—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
- B62D5/0457—Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by control features of the drive means as such
- B62D5/046—Controlling the motor
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/02—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for suppression of electromagnetic interference
- H02K11/026—Suppressors associated with brushes, brush holders or their supports
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/02—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for suppression of electromagnetic interference
- H02K11/028—Suppressors associated with the rotor
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
- H02K11/21—Devices for sensing speed or position, or actuated thereby
- H02K11/215—Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
- H02K11/30—Structural association with control circuits or drive circuits
- H02K11/33—Drive circuits, e.g. power electronics
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K9/00—Arrangements for cooling or ventilating
- H02K9/22—Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
- H02K9/227—Heat sinks
Definitions
- the present invention relates to a rotating electrical machine with a control device, an electric power steering device, and a manufacturing method of the rotating electrical machine with a control device, and more particularly to downsizing of the rotating electrical machine with a control device.
- An electric power steering device for a vehicle includes a rotating electric machine integrated with a control device (for example, Patent Documents 1 to 15).
- the control device is disposed on the counter-output shaft side of the rotating electrical machine (for example, Patent Document 1).
- a power module that supplies a drive current and a heat sink that absorbs heat generated by the power module are provided outside the case of the rotating electrical machine.
- the heat sink is connected to the periphery of the case of the rotating electrical machine via an intermediate member within the range of the outer diameter.
- the motor frame is equipped with a bearing that supports the non-output shaft side of the rotating electrical machine.
- a control board and a heat sink are arranged in the control device (for example, Patent Document 2).
- a rotation sensor that reads the rotation angle of the rotor is provided to face the sensor permanent magnet in the axial direction.
- the sensor permanent magnet is held at the end of the rotating shaft of the rotating electrical machine on the side opposite to the output shaft.
- the heat sink is in contact with the switching element of the rotating electrical machine drive circuit.
- a bearing on the side opposite to the output shaft is arranged on the heat sink, so that the shaft length is reduced and the number of parts is reduced.
- the bearing on the opposite side of the output shaft is arranged on the heat sink to reduce the shaft length and the number of parts. Since a noise reduction coil and a capacitor are arranged between the heat sink and the control board, the distance between the bearing on the non-output shaft side and the control board is large. When the shaft length of the rotating electrical machine is large, the size and weight of the rotating electrical machine increase. Further, since the noise reduction coil and the capacitor are arranged so as to be embedded in the heat sink, the volume of the heat sink is reduced and the heat capacity of the heat sink is reduced. Further, when heat is absorbed by bringing the switching element of the control board into contact with the heat sink, the distance between the heat sink and the control board is increased, so that the length of the protrusion is increased and the size and weight of the rotating electrical machine are increased.
- the present invention has been made to solve the above-described problems, and an object of the present invention is to reduce the size of a rotating electrical machine with a control device.
- the rotating electrical machine with a control device supports a rotor having a permanent magnet for a sensor attached to the rear side of the rotating shaft, a stator having a stator core and an armature winding, and a front side of the rotating shaft.
- a front housing to which the first bearing is fixed, a motor frame that is coupled to the front housing and accommodates the rotor and the stator, and a second bearing that supports the rear side of the rotating shaft is fixed.
- a smoothing capacitor, and a noise reduction coil connected to the plurality of switching elements.
- the microcomputer controls the drive circuit based on a signal from the rotation sensor to drive a plurality of switching elements, and at least one of the smoothing capacitor and the noise reduction coil is rear of the control board. It is arranged on the side.
- the heat sink also serves as the rear housing, the number of parts, the cost, and the axial size can be reduced.
- FIG. 3 is an explanatory diagram of the rotating electrical machine according to the first embodiment.
- Explanatory drawing FIG. 3A showing the first embodiment of the shaft holding portion
- explanatory drawing FIG. 3B showing the second embodiment of the shaft holding portion
- explanatory drawing FIG. 3C showing the third embodiment of the shaft holding portion. 3C).
- It is explanatory drawing which showed the circuit diagram of the control apparatus.
- It is sectional drawing FIG. 5A which shows a heat sink
- FIG. 5B which shows a heat sink.
- FIG. 6A is a cross-sectional view illustrating the configuration of the switching element
- FIG. 6B is a plan view illustrating the first configuration of the switching element
- FIG. 6C is a plan view illustrating the second configuration of the switching element. is there.
- FIG. 7A is a first cross-sectional view illustrating the configuration of the power module.
- FIG. 7B is a plan view illustrating a first configuration of the power module.
- FIG. 7C is a plan view illustrating a second configuration of the power module.
- FIG. 7D is a second cross-sectional view illustrating the configuration of the power module.
- FIG. 7E is a plan view illustrating a third configuration of the power module.
- FIG. 7F is a plan view illustrating a fourth configuration of the power module. It is sectional drawing (FIG.
- FIG. 8A which shows a 1st circuit wiring member, and a top view (FIG. 8B) which shows a 1st circuit wiring member.
- FIG. 9A which shows a control board
- FIG. 9B shows a control board.
- shaft rotating shaft
- FIG. 21B which shows the heat sink which concerns on Embodiment 2.
- FIG. 6 is an explanatory diagram of a rotating electrical machine according to Embodiment 3.
- FIG. 23A which shows the 1st circuit wiring member which concerns on Embodiment 4
- a top view (FIG. 23B) which shows the 1st circuit wiring member which concerns on Embodiment 4.
- FIG. 10 is an explanatory diagram of a rotating electrical machine according to a fifth embodiment. It is explanatory drawing of the rotary electric machine which concerns on Embodiment 6.
- FIG. FIG. 10 is an explanatory diagram of a rotating electrical machine according to a seventh embodiment.
- FIG. 10 is an explanatory diagram of a rotating electrical machine according to an eighth embodiment.
- FIG. 20 is an explanatory diagram of a rotating electrical machine according to a ninth embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a tenth embodiment.
- It is sectional drawing (FIG. 30A) which shows the heat sink concerning Embodiment 11, and the top view (FIG. 30B) which shows the heat sink concerning Embodiment 11.
- FIG. 31A which shows the rotary electric machine which concerns on Embodiment 12, and a top view (FIG. 31B) which shows the rotary electric machine which concerns on Embodiment 12.
- FIG. 32A which shows the rotary electric machine which concerns on Embodiment 13, and a top view (FIG.
- FIG. 32B which shows the rotary electric machine which concerns on Embodiment 13.
- FIG. 33A which shows the rotary electric machine which concerns on Embodiment 14, and a top view (FIG. 33B) which shows the rotary electric machine which concerns on Embodiment 14.
- FIG. 25 is an explanatory diagram of a rotating electrical machine according to a fifteenth embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a sixteenth embodiment. It is sectional drawing (FIG. 36A) which shows a 1st circuit wiring member, and a top view (FIG. 36B) which shows a 1st circuit wiring member. It is sectional drawing (FIG.
- FIG. 23 is an explanatory diagram of a rotating electrical machine according to a seventeenth embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to an eighteenth embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to the nineteenth embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a twentieth embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a twenty-first embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a twenty-second embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a twenty-third embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a twenty-fourth embodiment.
- FIG. 38 is an explanatory diagram of a rotating electrical machine according to a twenty-fifth embodiment.
- FIG. 1 is an explanatory diagram of an electric power steering apparatus 100 for an automobile according to an embodiment of the present invention.
- the control device 4 and the motor unit 5 are connected and integrated to form a rotating electrical machine 10.
- Power is supplied to the control device 4 of the rotating electrical machine 10 from a battery or an alternator via a connector 3a.
- the motor unit 5 of the rotating electrical machine 10 includes a stator 15 and a rotor 16.
- the torque is transmitted to the shaft 1c via the steering shaft 1b.
- the torque (torque signal) detected by the torque sensor 2 is converted into an electrical signal and transmitted to the control device 4 of the rotating electrical machine 10 via the connector 3b.
- vehicle information such as the vehicle speed is converted into an electrical signal and transmitted to the control device 4 of the rotating electrical machine 10 via the connector 3c.
- the rotating electrical machine 10 is arranged in a direction parallel to the moving direction of the rack shaft (see the direction of the arrow).
- the control device 4 calculates a necessary assist torque from the torque signal and the vehicle information, and supplies a current to the motor unit 5.
- the torque generated by the rotating electrical machine 10 is decelerated by the gear box 6 in which a belt and a ball screw are incorporated, and generates a thrust that moves the rack shaft 7a inside the rack housing 7 in the direction of the arrow. As a result, the tie rod 8 moves and the tire can be steered to turn the vehicle.
- the tie rod is a rod that connects the steering gear box to the knuckle arm of the wheel so that the steered wheel (mainly the front wheel) can be moved to the left and right in accordance with the steering operation.
- a driver whose steering force is assisted by the torque of the rotating electrical machine 10 can turn the vehicle with a small steering force.
- the rack boot 9 is provided so that foreign matter does not enter the apparatus.
- the rotating electrical machine 10 has a structure in which the control device 4 and the motor unit 5 are connected and integrated.
- a pulley 14 and a sensor permanent magnet 23 are attached to a rotating shaft 16 b of the rotating electrical machine 10.
- the rotating shaft 16b of the rotating electrical machine 10 the side on which the pulley 14 is attached is referred to as the front side (or the output shaft side).
- the side to which the sensor permanent magnet 23 is attached will be referred to as the rear side (or counter-output shaft side).
- the control device 4 is disposed on the rear side (or the opposite output shaft side) of the rotating electrical machine 10.
- the rotating electrical machine 10 and the control device 4 are substantially circular when viewed from the axial direction.
- the stator 15 of the rotating electrical machine 10 includes a stator core 15a formed by laminating electromagnetic steel plates and an armature winding 15b housed in the stator core 15a.
- the stator core 15a is fixed to the motor frame 22a.
- the front side housing 22b is provided on the front surface of the rotating electrical machine 10.
- the motor frame 22a and the front housing 22b are fixed with bolts 17e.
- the front housing 22b is provided with a front bearing 17a (first bearing).
- the front bearing 17a and the rear bearing 17b (second bearing) support the rotary shaft 16b in a rotatable manner.
- Three-phase (U-phase, V-phase, W-phase) armature windings 15b are wound around the teeth of the stator core 15a via insulators.
- the armature windings are connected to each other to form a three-phase connection.
- Each terminal of the three-phase connection is connected to a total of three motor terminals 21.
- the motor terminal may be composed of a conductor electrically connected to the armature winding of the motor, or may be composed of a terminal of a connection plate electrically connected to the armature winding. is there.
- the armature winding 15b generates heat because a current for driving the rotating electrical machine 10 flows. Therefore, the heat dissipation and cooling are performed via the motor frame 22a and the like.
- the rotating electrical machine 10 may have a structure in which a permanent magnet is embedded in the rotor core 16a, or a reluctance motor or induction machine that does not use a permanent magnet.
- the rotor 16 of the rotating electrical machine 10 includes a rotor core 16a, a rotating shaft 16b, a permanent magnet 16c, and the like.
- the rotor core 16a is press-fitted into the rotating shaft 16b.
- the permanent magnet 16c is fixed to the surface of the rotor core 16a.
- a sensor permanent magnet 23 is directly attached to the rear end of the rotating shaft 16b.
- the sensor permanent magnet 23 protrudes from the heat sink 20 to the rear side. Since the axial length of the rotation shaft 16b is shortened, the amount of eccentricity of the sensor permanent magnet 23 relative to the rotation sensor 24 can be reduced.
- the sensor permanent magnet 23 generates a magnetic flux on the rear side.
- a nonmagnetic holder may be attached between the rotating shaft 16b and the sensor permanent magnet 23.
- the controller 4 is equipped with a rotating electrical machine drive circuit having a switching element 12 for driving the rotating electrical machine 10.
- the switching element 12 includes a MOS-FET (Metal-Oxide Semiconductor Field Effect Transistor) and the like.
- the control device 4 is provided with a power supply connector 3a, a connector 3b for receiving a signal (torque signal) from the torque sensor 2, and a connector 3c for receiving vehicle information such as vehicle speed.
- the control device 4 includes a control board 13, a control device case 18, a circuit wiring member 26a (first circuit wiring member or first circuit wiring member), and a circuit wiring member 26b (second circuit wiring member or second circuit wiring member). It has.
- the circuit wiring member 26 a is disposed on the rear side of the heat sink 20 and on the front side of the control board 13.
- the circuit wiring member 26 b is disposed on the rear side with respect to the control board 13.
- the arrangement of the control board 13 having the small current components is arranged along a plane perpendicular to the rotating shaft 16 b of the rotating electrical machine 10.
- the control device 4 includes a smoothing capacitor 19, a common mode coil 11a, a normal mode coil 11b, and the like.
- the common mode coil 11 a and the normal mode coil 11 b are installed to reduce noise and are arranged on the rear side of the control board 13.
- the smoothing capacitor 19 provided for smoothing the current is disposed on the rear side of the control board 13.
- the control device 4 is covered with a control device case 18.
- the control device case 18 may be a resin, a metal such as aluminum, or a combination of a resin and a metal such as aluminum.
- the control device case 18 is configured to dissipate and cool by contacting the smoothing capacitor 19.
- Smoothing capacitor 19, common mode coil 11a and normal mode coil 11b are electrically connected by a bus bar.
- the noise reduction coil 11 and the smoothing capacitor 19 are arranged on the rear side of the control board 13. Even if at least one of the noise reduction coil 11 and the smoothing capacitor 19 is arranged on the rear side of the control board 13, the same effect can be obtained.
- the smoothing capacitor and the noise reduction coil is disposed on the rear side of the control board, at least one of the noise reduction coil 11 and the smoothing capacitor 19 is provided inside the heat sink. Placement can be avoided. In addition to securing the volume of the heat sink 20 per axial length, the heat capacity is improved while reducing the size of the heat sink 20 in the axial direction. Further, since at least one of the noise reduction coil 11 and the smoothing capacitor 19 is not disposed between the rear bearing 17b and the control board 13, the distance between the rear bearing 17b and the control board 13 is reduced. As a result, the size of the rotating electrical machine 10 can be reduced, and the rotating electrical machine 10 can be further reduced in weight.
- the smoothing capacitor 19 radiates and cools the periphery by contacting the control device case 18 directly or indirectly through resin or the like. Therefore, the temperature rise of the smoothing capacitor 19 is suppressed, and the reliability of the smoothing capacitor 19 is improved.
- a gap is provided between the end face of the smoothing capacitor 19 and the control device case 18. Therefore, even if the internal pressure of the smoothing capacitor 19 rises, the control device case 18 does not get in the way, the housing of the smoothing capacitor 19 can swell, and the internal pressure can be lowered. However, the smoothing capacitor 19 and the control device case 18 may not be in contact with each other. *
- the structure of the rotating shaft 16b of the rotating electrical machine 10 will be described with reference to FIGS. 3A to 3C.
- the rotary shaft 16b is provided with shaft holding portions 16d at both ends so that the rotary shaft 16b can be fixed from both ends.
- the shaft holding portion 16d is a concentric recess that is concentric with the shaft provided in the central portion of the shaft.
- the shaft holding portion is a shaft protruding portion that is concentric with the shaft provided in the central portion of the shaft.
- the shaft holding portion is a cutout portion provided in a part of the shaft end portion. In either case, the same effect can be obtained.
- a pulley 14 is press-fitted into one end of the rotating shaft 16b, that is, the front side. The pulley 14 transmits driving force to the belt of the electric power steering device.
- FIG. 4 shows an example of a circuit diagram of the control device.
- the control device 4 is provided with a connector 3a for supplying power, a connector 3b for receiving a torque signal from the torque sensor 2, and a connector 3c for receiving vehicle information such as vehicle speed.
- the armature winding 15b of the stator 15 is Y-connected.
- Three switching elements 12 are provided to correspond to each of the three phases. Each switching element 12 is mounted with a MOS-FET 12a, a MOS-FET 12b, a MOS-FET 12c, and a shunt resistor 12d.
- the MOS-FET 12a constitutes the U phase + side arm
- the MOS-FET 12b constitutes the U phase ⁇ side arm.
- One end of the MOS-FET 12 a is connected to a smoothing capacitor 19 for smoothing current and a noise reduction coil (particularly a normal mode coil) 11.
- One end of the MOS-FET 12b is connected to the ground potential portion of the vehicle via a shunt resistor 12d.
- the connection point between the MOS-FET 12a and the MOS-FET 12b is the U-phase AC side terminal of the three-phase bridge circuit.
- the MOS-FET 12c has one end connected to the U-phase AC side terminal and the other end connected to the U-phase terminal of the armature winding 15b.
- the W-phase switching element 12 and the V-phase switching element 12 have the same configuration.
- the MOS-FET 30a and the MOS-FET 30b mounted on the power supply relay 30 are connected to each other at one end.
- the other end of the MOS-FET 30a is connected to the + side DC terminal of the three-phase bridge circuit via the noise reduction coil 11.
- the other end of the MOS-FET 30b is connected to a battery 31 mounted on the vehicle via a connector 3a.
- the FET drive circuit 13b mounted on the control board 13 has its output terminal connected to the gates of the MOS-FETs 12a to 12c.
- the FET drive circuit 13b gives a gate drive signal to each of these gates at a predetermined timing.
- a torque signal and vehicle information are input to the microcomputer 13a mounted on the control board 13 from the connector 3b and the connector 3c, respectively.
- the microcomputer 13 a controls the output timing of the gate drive signal output from the FET drive circuit 13 b based on the rotation detection signal from the rotation sensor 24.
- Various capacitors and coils are mounted on the control device.
- the common mode coil 11a and the normal mode coil 11b are the first and second largest, respectively.
- the smoothing capacitor is the first largest.
- the smoothing capacitor 19 installed to smooth the current has the maximum capacity. It goes without saying that a plurality of (for example, three) smoothing capacitors may be arranged.
- the heat sink 20 is provided with a heat sink convex portion 20a that fits with the motor frame 22a.
- the thermal resistance between the heat sink 20 and the motor frame 22a is lowered. More heat of the heat sink 20 can be transmitted to the motor frame 22a, and the heat capacity of the heat sink 20 can be improved, so that the cooling performance of the switching element 12 is improved.
- the thermal expansion coefficients of both are equal, and the fixing strength of the motor frame 22a and the heat sink 20 when the temperature of the motor unit 5 changes is improved.
- the motor frame 22a and the heat sink 20 can be reduced in weight and improved in thermal conductivity.
- the heat sink 20 is shrink-fitted, press-fitted, or screwed to the motor frame 22a using the heat sink protrusion 20a.
- the heat sink 20 is fixed to the motor frame 22a of the rotating electrical machine 10 by shrink fitting.
- shrink fitting By fixing the heat sink 20 to the motor frame 22a in this way, the heat of the heat sink 20 is efficiently transmitted to the motor frame 22a.
- shrink fitting or press fitting the thermal resistance between the heat sink 20 and the motor frame 22a is greatly reduced, and a larger amount of heat generated in the heat sink 20 can be transmitted to the motor frame 22a. Since the heat capacity of the heat sink 20 is improved, the cooling performance of the switching element 12 can be improved.
- the heat sink 20 has a substantially circular shape when viewed from the axial direction in order to increase the volume. As shown in FIG. 5B, the rear surface of the heat sink 20 is provided with three switching element arrangement portions 20c and one switching element arrangement portion 20h. Further, three electrical wiring through holes 20 d that penetrate the heat sink 20 are provided. Each of the switching element arrangement portions 20c corresponds to a three-phase switching element. The switching element placement unit 20 h corresponds to the power relay 30. The three motor terminals 21 pass through the respective electric wiring through holes 20d. At this time, since each electric wiring through-hole can be reduced, the volume of the heat sink can be increased, and the heat capacity of the heat sink can be improved, so that the cooling performance of the switching element can be improved.
- the outer diameter of the sensor permanent magnet 23 is larger than the minimum outer diameter of the shaft through hole 20b of the heat sink 20. Therefore, the sensor through magnet 23 having a large outer diameter can be used while the shaft through hole 20b of the heat sink 20 can be reduced and the heat capacity of the heat sink 20 can be improved.
- the magnetic field generated from the sensor permanent magnet 23 becomes uniform, and the accuracy of the rotation sensor 24 is improved.
- the sensor permanent magnet 23 protrudes from the heat sink 20 to the rear side. It is not necessary to provide a sensor permanent magnet having a larger outer diameter than the minimum outer diameter portion of the shaft through hole 20b in the heat sink 20, and the volume of the heat sink 20 can be increased.
- the heat capacity of the heat sink can be improved and the heat capacity of the heat sink 20 is improved, the cooling performance of the switching element 12 is improved. Further, the distance between the sensor permanent magnet 23 and the control board 13 can be reduced, the magnetic field generated from the sensor permanent magnet 23 becomes uniform, and the accuracy of the rotation sensor 24 is improved.
- the control device is mounted with a rotating electrical machine drive circuit for driving the rotating electrical machine.
- This rotating electrical machine drive circuit has a switching element 12 having a MOS-FET or the like.
- the switching element 12 generates heat because a current for driving the rotating electrical machine flows. Therefore, the switching element 12 is brought into contact with the switching element arrangement portion 20c of the heat sink 20 via an adhesive, an insulating sheet, or the like to radiate and cool.
- the switching element 12 in contact with the heat sink 20 has a structure in which a bare chip is mounted on a DBC (Direct Bonded Copper) substrate 12s.
- DBC Direct Bonded Copper
- the switching elements 12 are arranged so as to surround one power relay 30 and are arranged at intervals of about 90 degrees on the circumference.
- the power relay 30 has bare chips of a MOS-FET 30a and a MOS-FET 30b.
- the three-phase switching element 12 includes a MOS-FET 12a, a MOS-FET 12b, a MOS-FET 12c, and a shunt resistor 12d.
- the terminal 12t of the switching element is electrically connected to the ends of three motor terminals wired from the rotating electrical machine to the control device side by welding, press-fit, solder, or the like.
- one of the three switching elements plays a role of electrically disconnecting the rotating electrical machine when necessary, that is, a role of a motor relay.
- the switching element has three phases, the number of phases may be different, such as two phases, five phases, and six phases, and the number of switching elements may be other than three.
- the terminal 12t of the switching element is electrically connected to the ends of three motor terminals wired from the rotating electrical machine to the control device side by welding, press-fit, solder, or the like.
- the terminal 12t of the switching element may be electrically connected to the circuit wiring member by welding, press fit, solder, or the like, and may further be electrically connected to the motor terminal by welding, press fit, solder, or the like.
- FIG. 6C also shows the case where a power relay is not provided.
- the switching elements 12 are arranged at intervals of approximately 120 degrees. A large area of the switching element can be ensured, heat generated by the switching element can be efficiently transmitted to the switching element arrangement portion, and an effect of reducing a temperature rise of the switching element can be obtained.
- connection portions such as wire bonding for electrically connecting the bare chip and the shunt resistor 12d are omitted.
- the three-phase switching element 12 has a common design and can be reduced in cost.
- the switching element 12 may be configured as a power module in which the bare chip is sealed with resin.
- the heat generated by the switching element 12m can be efficiently transmitted to the switching element arrangement portion, and the effect of reducing the temperature rise of the switching element 12m can be obtained.
- a circuit terminal 27b may be provided in the switching element 12.
- the circuit wiring member 26 includes a circuit wiring member 26 a disposed on the rear side of the heat sink 20 and on the front side of the control board 13, and a circuit wiring member 26 b disposed on the rear side of the control board 13. .
- the circuit wiring member 26a includes a bus bar 26c, a frame 26d, a positioning portion 26e, a power supply terminal 27a, a circuit terminal 27b, and the like.
- the frame 26d is made of an insulating member such as resin and holds the bus bar 26c and the like.
- the frame 26d may be integrally formed with the bus bar 26c.
- the bus bar 26c of the circuit wiring member 26a is connected to the power supply terminal 27a.
- the power supply terminal 27a is connected to the power supply connector 3a.
- Bus bar 26 c is connected to switching element 12. That is, the power supplied from the connector 3a is supplied to the switching element 12.
- the circuit terminal 27b may be provided in the switching element without being provided in the circuit wiring member. In this case, the circuit wiring member is not provided with a circuit terminal.
- FIG. 9A is a side view showing the control board.
- FIG. 9B is a schematic view of the control board as viewed from the front side. In the figure, details of the circuit are omitted, and only a part of the small current component is drawn.
- the control board 13 has a thin plate shape and has a substantially circular shape when viewed from the axial direction in order to secure an area for attaching components and wiring patterns. Based on the information received from the connector 3b and the input terminal of the connector 3c, the control board 13 sends a control signal to the switching element 12 in order to appropriately drive the rotating electrical machine. At this time, among the small current components of the control board 13, the microcomputer 13a and the FET drive circuit 13b generate a larger amount of heat than other components because current flows.
- the plurality of circuit terminals 27b individually pass through the plurality of through holes 13e and extend to the circuit wiring member 26b, and are connected to the smoothing capacitor 19 and the noise reduction coil 11.
- the control signal is transmitted by the control board 13 and the circuit wiring member 26a, the control board 13 and the circuit wiring member 26b, and the circuit terminal 27b that electrically connects the control board 13 and the switching element 12.
- the circuit terminal 27b is fixed to the control board, the circuit wiring member, and the switching element by wire bonding, press fit, solder, or the like.
- the control board 13 has a through hole 13d through which the power supply terminal 27a passes, a through hole 13e through which the circuit terminal 27b passes, and a positioning portion 13c.
- the circuit terminal 27b passes through the through hole 13e and is connected to the control board.
- the microcomputer 13a and the FET drive circuit 13b are arranged on the front side, but it goes without saying that they may be arranged on the rear side.
- a rotation sensor 24 is mounted on the front side of the control board 13.
- the rotation sensor 24 is arranged at a position coaxial with and close to the sensor permanent magnet 23.
- the rotation sensor 24 detects the magnetism generated by the sensor permanent magnet 23 and detects the rotation angle of the rotor 16 by knowing its direction.
- the microcomputer 13a calculates an appropriate drive current according to the rotation angle, and controls the FET drive circuit 13b. Since the rotation sensor 24 is disposed on the control board 13, the wiring between the rotation sensor 24 and the control board 13 can be shortened, and resistance to noise flowing into the rotation sensor 24 from the outside is improved. Further, since the mechanism for holding the rotation sensor 24 can be omitted, the number of parts can be reduced.
- the control board 13 includes a positioning part 13c.
- the control board 13 can be positioned between the heat sink 20 and the positioning part of the circuit wiring member 26. Since the relative position of the heat sink and the control board is determined, assembly is simplified, adjustment of the rotation sensor 24 is unnecessary, and the accuracy of the rotation sensor 24 can be improved.
- the rotation sensor 24 is mounted on the control board, but the rotation sensor 24 may be mounted on a board different from the control board or held by another member.
- FIG. 10 is a side view of the circuit wiring member 26b.
- the circuit wiring member 26b disposed on the rear side of the control board 13 includes a bus bar 26c, a common mode coil 11a, a normal mode coil 11b, a smoothing capacitor 19, a circuit terminal (input terminal) 27b, etc., which are welded or press-fit, soldered, etc. Are electrically connected. Since the noise reduction coil 11, the smoothing capacitor 19, and the circuit wiring member 26 are arranged on the rear side of the position where the bearing 17b is inserted, the failure of the rotating electrical machine when these components fall out inside the rotating electrical machine. Can be prevented. In addition, circuit wiring members 26 a and 26 b are provided between the switching element that contacts the heat sink 20 and the noise reduction coil 11. The noise of the switching element 12 is shielded by the bus bar 26c of the circuit wiring member, and the magnetic coupling between the switching element and the noise reducing coil 11 can be reduced.
- the electric power steering apparatus 100 is configured.
- the torque sensor 2 detects the steering torque and transmits a torque signal to the microcomputer 13a.
- a rotation detection signal corresponding to the steering rotation speed detected by the rotation sensor 24 is also input to the microcomputer 13a.
- the microcomputer 13a calculates an assist torque based on the input steering torque, steering rotation speed, vehicle speed signal, and the like.
- the assist torque is generated in the rotating electrical machine 10 by the FET drive circuit 13b controlling the rotating electrical machine drive circuit (three-phase bridge circuit), and is applied to the steering shaft 1b via the speed reduction mechanism.
- the FET drive circuit 13b generates a gate drive signal at a predetermined timing based on an instruction from the microcomputer 13a, and controls conduction of the MOS-FET of the three-phase bridge circuit.
- the three-phase bridge circuit generates a predetermined three-phase alternating current and supplies the three-phase alternating current to the armature winding 15b of the stator 15.
- the rotating electrical machine 10 is driven, and the torque generated by the rotating electrical machine 10 is applied as an assist torque to the steering shaft 1b via the speed reduction mechanism. Thereby, the steering force of the steering wheel (handle) 1a by the driver is reduced.
- the armature winding 15b is shown as being Y-connected, it goes without saying that it may be ⁇ -connected.
- the switching element 12 has three phases, the number of phases may be different, such as two phases, five phases, and six phases.
- At least one of a noise reduction coil and a capacitor is not arranged inside the heat sink and between the rear bearing and the control board.
- the axial length is reduced, the volume of the heat sink can be increased to improve the heat capacity, and the distance between the rear bearing and the control board can be reduced, so that the rotating electrical machine can be reduced in size and weight.
- the motor part of the rotating electrical machine is assembled.
- the U-phase, V-phase, and W-phase windings are wound around the teeth of the stator core via an insulator to form a three-phase armature winding.
- the winding start and the winding end of each U-phase winding are connected to each other to complete the U-phase armature winding.
- V-phase and W-phase armature windings are completed.
- the winding start and end of the U-phase armature winding, the V-phase armature winding, and the W-phase armature winding are connected to each other to complete the three-phase connection.
- Each terminal of the three-phase connection is connected to the motor terminal 21.
- the stator core is press-fitted into the motor frame.
- a step of fixing the switching element 12 to the heat sink 20 is included.
- a shaft through hole 20b that is smaller than the outer diameter of the bearing 17b and larger than the inner diameter of the bearing 17b is formed on the rear side of the bearing 17b.
- the switching element 12 including a MOS-FET, a bare chip, a shunt resistor, and the like is bonded and fixed to the switching element arrangement portion 20c of the heat sink 20 with a highly heat conductive adhesive.
- the power relay 30 is bonded and fixed to the switching element arrangement portion 20h of the heat sink 20 with a high thermal conductive adhesive.
- the outer ring of the rear bearing 17b is fixed to the shaft through hole 20b of the heat sink.
- the stator motor frame 22a is shrink-fitted into the heat sink 20, and fixed by press-fitting, screwing, or the like.
- the motor terminal 21 to which the three-phase connection terminal is connected is inserted into the electric wiring through hole 20 d provided in the heat sink 20.
- the motor terminal 21 protrudes to the rear side from the heat sink 20.
- the motor terminal 21 and the switching element 12 are electrically connected by welding, press-fit, solder, or the like. However, if the motor frame and the heat sink are integrated, this step is omitted.
- the shaft holding jig 16h is fixed to the shaft holding portions 16d at both ends of the rotating shaft 16b, and the rotating shaft 16b is fixed from both ends. Thereafter, the rotor core 16a is press-fitted into the rotating shaft 16b. Further, as shown in FIG. 14, a permanent magnet 16c is bonded and fixed to the rotor core 16a. The permanent magnet 16c may be magnetized before bonding, or may be magnetized by a magnetizer after bonding and fixing.
- the outer ring of the front bearing 17a is fixed to the shaft through hole 22d of the front housing 22b.
- the shaft holding jig 16h is passed through the shaft through hole 22d of the front housing 22b. Further, a bearing 17a on the front side of the housing is press-fitted into the rotary shaft 16b to a predetermined position.
- the shaft holding jig 16 h is passed through the shaft through hole 20 b of the heat sink 20.
- the rotation shaft 16b of the rotor 16 held by the shaft holding jig 16h is inserted into the rear bearing 17b, and the rear bearing 17b of the heat sink is press-fitted to a position where the motor frame 22a contacts the front housing 22b.
- the sensor permanent magnet 23 magnetized from the rear side is fixed to the rear end of the rotating shaft 16b.
- the sensor permanent magnet 23 may be magnetized by a magnetizer after being fixed to the rotating shaft 16b.
- the circuit wiring member 26a in which the bus bar 26c, the power supply terminal 27a, the circuit terminal 27b and the like are integrally molded with the resin is fixed to the rear side of the heat sink 20 using an adhesive, a screw, or the like.
- the switching element 12 and the bus bar 26c of the circuit wiring member 26a are electrically connected by welding, wire bonding, press fit, solder, or the like.
- cream solder After applying cream solder to the control board 13, small current components such as the microcomputer 13a, the FET drive circuit 13b, the rotation sensor 24, and peripheral circuit elements thereof are mounted. Thereafter, the cream solder is melted using a reflow device, and these components are soldered.
- control board 13 is attached to the rear side of the heat sink 20 and the circuit wiring member 26a.
- the positioning part 13c of the control board 13 is fitted with the positioning part provided on the circuit wiring member 26a, so that the rotation sensor 24 provided on the control board 13 and the sensor permanent provided on the end of the rotary shaft. Positioning with the magnet 23 is performed.
- the control board 13, the circuit wiring member 26b, and the circuit terminal 27b are electrically connected by wire bonding, press fit, solder, or the like.
- a circuit wiring member 26b in which the bus bar is integrally molded with resin and the common mode coil 11a, the normal mode coil 11b, and the smoothing capacitor 19 are attached is arranged on the rear side of the control board 13.
- Wiring (power supply terminal 27a and circuit terminal 27b) extending from the circuit wiring member 26a to the rear side of the control board 13 and wiring extending from the control board 13 to the rear side (circuit terminal 27b) are arranged on the rear side of the control board.
- the circuit wiring member 26b is electrically connected by welding, press-fit, solder, or the like.
- the control device case 18 is attached from the rear side, and fixed to the heat sink 20 with an adhesive, screws, or the like.
- the step of fixing the motor frame to the heat sink is performed. Since the motor terminal does not protrude from the heat sink in the step of fixing the switching element, an effect that the assembling property is improved can be obtained.
- a process of fixing the sensor permanent magnet to the shaft is performed. Since the sensor permanent magnet having a diameter larger than the minimum portion of the shaft through hole of the heat sink can be attached to the rear side, the magnetic field of the sensor permanent magnet becomes uniform, and the accuracy of the rotation sensor 24 is improved. In particular, it is useful when the outer diameter of the sensor permanent magnet is larger than the outer diameter of the rotating shaft.
- the motor frame, heat sink and housing can be assembled while the shaft is fixed from both sides, and the rotor and the rotor are fixed when the stator and rotor are assembled. It becomes possible to prevent the contact of the child.
- FIG. 21A and 21B are explanatory views of a rotating electrical machine according to Embodiment 2 of the present invention.
- the basic heat sink structure is the same as in the first embodiment.
- the three motor terminals 21 are configured to pass through one electric wiring through hole 20d.
- the heat sink 20 is provided with a control board 13 having a small current component adjacent to the rear side.
- the volume of the heat sink can be improved, and the heat capacity of the heat sink can be improved, so that the cooling performance of the switching element is improved.
- the motor terminal passes through the electrical wiring through hole, it goes without saying that the same effect can be obtained even when electrical wiring such as signal wires and cables between other rotating electrical machines and the control device penetrates. Yes.
- FIG. FIG. 22 is an explanatory diagram of a rotary electric machine according to Embodiment 3 of the present invention.
- the basic structure is the same as in the first embodiment.
- the three-phase connection of the armature windings is connected to the motor terminal 21 via the ring-shaped connection plate 25.
- the armature windings of the stator core 15a are connected to each other to form a three-phase connection.
- the connection board 25 is disposed between the motor terminal 21 and the armature winding 15b.
- FIG. 23A and 23B are explanatory views of a rotating electrical machine according to Embodiment 4 of the present invention.
- the basic structure is the same as in the first embodiment.
- the switching element 12 is configured integrally with the circuit wiring member 26a.
- the circuit wiring member 26a includes a bus bar 26c, a frame 26d, a power supply terminal 27a, a circuit terminal 27b, and the like.
- the frame 26d is made of an insulating member such as resin and holds the bus bar 26c and the like.
- the bus bar 26c of the circuit wiring member 26a is connected to the power supply terminal 27a.
- FIG. FIG. 24 is an explanatory diagram of a rotary electric machine according to Embodiment 5 of the present invention. Since the basic structure is the same as that of the first embodiment, the sensor permanent magnet 23 will be supplementarily described with reference to the drawings. Although the sensor permanent magnet 23 protrudes rearward from the heat sink, the same effect can be obtained even if at least a part of the sensor permanent magnet 23 sinks and is buried in the heat sink.
- the heat sink 20 has a rear recess 20j. The sensor permanent magnet 23 is sunk and buried in the rear recess 20j.
- FIG. FIG. 25 is an explanatory diagram of a rotary electric machine according to Embodiment 6 of the present invention. Since the basic structure is the same as that of the first embodiment, the housing will be described supplementarily with reference to the drawings.
- the motor frame 22a is integrated with a front housing 22b provided on the front surface of the rotating electrical machine. At this time, since the thermal resistance between the housing and the motor frame is lowered, the cooling performance of the motor frame is improved, the coaxiality of the shaft and the motor frame is improved, and the vibration of the rotating electrical machine can be reduced.
- FIG. FIG. 26 is an explanatory diagram of a rotary electric machine according to Embodiment 7 of the present invention. Since the basic structure is the same as that of the first embodiment, the motor frame will be supplementarily described with reference to the drawings.
- the motor frame 22 a is integrated with the heat sink 20. At this time, since the thermal resistance between the heat sink 20 and the motor frame 22a is lowered, the cooling performance of the switching element 12 is improved. Further, the coaxiality between the rotating shaft 16b and the motor frame 22a is improved, and the vibration of the rotating electrical machine 10 can be reduced.
- FIG. 27 is an explanatory diagram of a rotary electric machine according to Embodiment 8 of the present invention.
- the basic structure is the same as in the first embodiment.
- a noise shielding member 33 is disposed around the noise reduction coil 11.
- the figure shows an example in which a noise shielding member 33 is inserted between the common mode coil 11a and the normal mode coil 11b. By doing in this way, it becomes possible to reduce the magnetic coupling of the common mode coil 11a and the normal mode coil 11b which are arrange
- the noise shielding member 33 include a metal plate.
- the noise reducing coil 11 and the smoothing capacitor 19 are arranged on the rear side of the control board 13. It goes without saying that the same effect can be obtained even if at least one of the noise reduction coil 11 and the smoothing capacitor 19 is arranged on the rear side of the control board 13.
- FIG. FIG. 28 is an explanatory diagram of a rotary electric machine according to Embodiment 9 of the present invention.
- the basic structure is the same as in the first embodiment.
- the smoothing capacitor 19 and the common mode coil 11 a are arranged on the rear side of the control board 13.
- the normal mode coil 11b is disposed on the circuit wiring member 26a and partially overlaps the control board 13 in the axial direction. Although the normal mode coil 11b partially overlaps the control board 13 in the axial direction, it is needless to say that the smoothing capacitor 19 or the common mode coil 11a may be used.
- the noise reducing coil 11 is composed of a common mode coil 11a and a normal mode coil 11b. It goes without saying that the same effect can be obtained even if only one of them is configured.
- FIG. FIG. 29 is an explanatory diagram of a rotary electric machine according to Embodiment 10 of the present invention.
- the basic structure is the same as in the first embodiment.
- the heat sink 20 has a rear-side protruding portion 20 e protruding to the control board 13.
- the ring-shaped or columnar rear protrusion 20e is in contact with at least one of the heat generating components (microcomputer 13a, FET drive circuit 13b, etc.) of the control board 13 through grease or the like, or is disposed close to the heat generating components. ing. Therefore, the heat dissipation and cooling performance of the heat generating component of the control board 13 can be improved.
- the noise reduction coil 11 and the smoothing capacitor 19 are disposed on the rear side of the circuit wiring member 26b, the distance between the rear side bearing 17b and the control board 13 is reduced, and as a result, the rear side protrusion The part 20e can be shortened, and the rotating electrical machine can be reduced in size and weight.
- the rear projection 20e of the heat sink may be used for positioning the heat sink 20 and the control board 13. Since the relative position of the heat sink and the control board is determined, assembly is simplified, adjustment is not required, and the accuracy of the rotation sensor 24 of the control board can be improved.
- the rear side protrusion part 20e shall be in contact with the heat-emitting component of a control board via grease.
- the rear-side protruding portion 20e is in contact with the control board via grease or the like, and the same effect can be obtained even if the heat-generating component of the control board is arranged close to the contact surface between the control board and the protrusion. Needless to say.
- the rear-side protruding portion 20e is in contact with the control board via grease or the like, the same effect can be obtained even if the rear-side protruding portion 20e is in direct contact with or close to the heat-generating component.
- FIG. 30A and 30B are explanatory views of a rotating electrical machine according to Embodiment 11 of the present invention.
- the basic structure is the same as in the first embodiment.
- a heat insulating material 20 f is inserted between the rear bearing 17 b and the heat sink 20.
- FIG. 31A and 31B are explanatory diagrams of a rotating electrical machine according to Embodiment 12 of the present invention.
- the basic structure is the same as in the first embodiment.
- the heat sink 20 includes a front side protruding portion 20g that protrudes to the front side at a position overlapping the connecting plate 25 in the axial direction. Therefore, the heat capacity of the heat sink can be improved, and the cooling performance of the switching element can be improved.
- the rear bearing is disposed on the front protruding portion 20g. Therefore, the distance between the bearings on the rear side can be reduced, and the vibration of the rotating electrical machine can be suppressed.
- the heat sink is provided with a ring-shaped front side recess 20i for accommodating the connection plate 25 protruding to the rear side of the rotating electrical machine. Therefore, the rotating electrical machine can be reduced in size.
- FIG. 32A and 32B are explanatory diagrams of a rotating electrical machine according to Embodiment 13 of the present invention.
- the basic structure is the same as in the first embodiment.
- the heat sink 20 is provided with a front side protruding portion 20g that protrudes to the front side at a position overlapping with the coil end on the rear side of the armature winding in the axial direction. Therefore, the heat capacity of the heat sink can be improved, and the cooling performance of the switching element can be improved.
- the rear bearing is disposed on the front protruding portion 20g. Therefore, the distance between the bearings on the rear side can be reduced, and the vibration of the rotating electrical machine can be suppressed.
- the heat sink also includes a ring-shaped front side recess 20i that houses a coil end of an armature winding that protrudes to the rear side of the rotating electrical machine. Therefore, the rotating electrical machine can be reduced in size.
- FIG. 33A and 33B are explanatory views of a rotating electrical machine according to Embodiment 14 of the present invention.
- the basic structure is the same as in the first embodiment.
- the rotor 16 is provided with a protruding portion 20k protruding to the front side at a position overlapping the rotor core recess 16g in the axial direction. Therefore, the heat capacity of the heat sink 20 can be improved, and the cooling performance of the switching element 12 can be improved.
- the rear bearing 17b is disposed on the protruding portion 20k. Therefore, the distance between the bearings on the rear side can be further reduced, and the vibration of the rotating electrical machine can be suppressed.
- the heat sink 20 includes a ring-shaped front side recess 20 i that houses a coil end of an armature winding that protrudes to the rear side of the rotating electrical machine. Therefore, the rotating electrical machine can be reduced in size.
- FIG. FIG. 34 is an explanatory diagram of a rotary electric machine according to Embodiment 15 of the present invention. Since the basic structure is the same as that of the first embodiment, the heat sink will be supplementarily described with reference to the drawings.
- the switching element 12 is bonded to the heat sink 20.
- the rear bearing 17 b is supported by the rear housing 34. As described above, since the rear side housing 34 is provided, the number of components increases, but the temperature rise of the rear side bearing 17b is suppressed, so that the life of the rotating electrical machine is extended.
- FIG. FIG. 35 is an explanatory diagram of a rotary electric machine according to Embodiment 16 of the present invention.
- the circuit wiring member 26 a is one member disposed on the rear side of the heat sink 20 and on the front side of the control board 13.
- the bus bar 26c, the common mode coil 11a, the normal mode coil 11b, the smoothing capacitor 19, the circuit terminal (input terminal) 27b, and the like are electrically connected by welding, press fitting, solder, or the like. Since the noise reduction coil 11, the smoothing capacitor 19, and the circuit wiring member 26a are arranged on the rear side from the position where the bearing 17b is inserted, the failure of the rotating electrical machine when these components fall into the rotating electrical machine. Can be prevented.
- a circuit wiring member 26 a is provided between the switching element 12 mounted on the heat sink 20 and the noise reduction coil 11.
- the noise of the switching element 12 is shielded by the bus bar 26c of the circuit wiring member 26a, and the magnetic coupling between the switching element and the noise reduction coil 11 can be reduced.
- FIG. 36A and FIG. 36B show an example of the circuit wiring member 26a.
- the circuit terminal 27f is connected to the normal mode coil 11b.
- the circuit terminal 27 g is connected to the smoothing capacitor 19.
- the circuit terminal 27h is connected to the common mode coil 11a.
- FIG. 37A is a side view showing the control board.
- FIG. 37B is a schematic view of the control board as viewed from the front side.
- a circuit terminal 27f connected to the normal mode coil 11b passes through the through hole 13f.
- a circuit terminal 27g connected to the smoothing capacitor 19 passes through the through hole 13g.
- a circuit terminal 27h connected to the common mode coil 11a passes through the through hole 13h.
- the plurality of circuit terminals 27 b individually pass through the plurality of through holes 13 e and extend to the rear side of the control board 13, and are connected to the smoothing capacitor 19 and the noise reduction coil 11.
- FIG. FIG. 38 is an explanatory diagram of a rotary electric machine according to Embodiment 17 of the present invention.
- a circuit wiring member 26 b is disposed on the rear side of the heat sink 20 and the control board 13.
- the bus bar 26c, the common mode coil 11a, the normal mode coil 11b, the smoothing capacitor 19, the power supply terminal 27a, the circuit terminal (input terminal) 27b, and the like are electrically connected by welding, press fitting, solder, or the like. Yes.
- a circuit wiring member 26b on which the noise reduction coil 11 and the smoothing capacitor 19 are mounted is disposed on the rear side of the position where the bearing 17b is inserted.
- the sensor permanent magnet 23 is directly attached to the rear end of the rotating shaft 16b.
- the sensor permanent magnet 23 protrudes from the heat sink 20 to the rear side. Since the axial length of the rotating shaft 16b is shortened, the rotating electrical machine can be reduced in size and weight, and the eccentric amount of the sensor permanent magnet 23 relative to the rotation sensor 24 can be reduced. Further, since at least one of the noise reduction coil 11 and the smoothing capacitor 19 is not disposed between the rear bearing 17b and the control board 13, the distance between the rear bearing 17b and the control board 13 is reduced. As a result, the size of the rotating electrical machine 10 in the axial direction can be reduced, and the rotating electrical machine 10 can be reduced in weight.
- the smoothing capacitor 19 radiates and cools the surroundings by directly contacting the control device case 18 directly or through resin or the like. Therefore, the temperature rise of the smoothing capacitor 19 is suppressed, and the reliability of the smoothing capacitor 19 is improved.
- the control device case 18 is made of a metal such as aluminum
- the smoothing capacitor 19 is in contact with a metal member having a high thermal conductivity, so that the heat of the smoothing capacitor 19 can be released to the periphery of the rotating electrical machine.
- the temperature rise of the smoothing capacitor is further suppressed, and the reliability of the smoothing capacitor is improved.
- the smoothing capacitor fails.
- FIG. 39 is an explanatory diagram of a rotary electric machine according to Embodiment 18 of the present invention.
- the control device case 18 is made of an insulating member having a low thermal conductivity such as resin, and is connected to the heat sink 20 (first case). Member) and a case member 18b (second case member) made of a metal such as aluminum.
- the smoothing capacitor 19 is in contact with the case member 18b. Since the thermal conductivity between the heat sink 20 and the case member 18b can be lowered, the heat from the heat sink 20 to the control device case 18 can be reduced. Therefore, since the temperature rise of the smoothing capacitor 19 is suppressed, the reliability of the smoothing capacitor is further improved and the torque reduction of the rotating electrical machine can be further suppressed.
- the smoothing capacitor 19 and the noise reduction coil 11 are both disposed on the rear side of the control board 13. Needless to say, at least one of the smoothing capacitor 19 and the noise reduction coil 11 may be arranged on the rear side of the control board 13. If both the smoothing capacitor 19 and the noise reduction coil 11 are disposed on the rear side of the control board 13, the arrangement of the noise reduction coil 11 and the smoothing capacitor 19 inside the heat sink 20 can be avoided. In addition to further securing the volume of the heat sink 20 per axial length, the heat capacity is improved while further reducing the size of the heat sink 20 in the axial direction.
- the noise reduction coil 11 and the smoothing capacitor 19 are not disposed between the rear bearing 17b and the control board 13, the distance between the rear bearing 17b and the control board 13 is reduced. As a result, the size of the rotating electrical machine 10 in the axial direction can be reduced, and the rotating electrical machine 10 can be reduced in weight. Since the axial length of the rotating shaft 16b is further shortened, the rotating electrical machine can be reduced in size and weight, and the amount of eccentricity of the sensor permanent magnet 23 relative to the rotation sensor 24 can be reduced.
- the armature winding 15b and the switching element 12 of the rotating electrical machine 10 generate heat when current is supplied.
- the heat sink 20 is in contact with the switching element 12 and absorbs heat.
- the armature winding 15b, the switching element 12, and the heat sink 20 are supplied to the rotating electrical machine from the viewpoint of preventing the smoothing capacitor and the noise reduction coil 11 from being damaged in order to raise the temperatures of the smoothing capacitor 19 and the noise reduction coil 11 that are close to each other. It is necessary to suppress the current.
- the temperature increases, the torque of the rotating electrical machine decreases. Further, the reliability of the smoothing capacitor 19 is lowered.
- the smoothing capacitor and the noise reduction coil are arranged on the rear side of the control board, the smoothing capacitor and the noise reduction coil are arranged far from the armature winding, the switching element, and the heat sink of the rotating electric machine. Therefore, the temperature rise of the smoothing capacitor and the noise reduction coil can be suppressed.
- control board 13 and the circuit wiring member 26b are interposed between the smoothing capacitor, the noise reduction coil and the armature winding, the switching element, and the heat sink, the control board 13 and the circuit wiring member 26b are insulated from each other, and the smoothing capacitor and the noise reduction are performed.
- the temperature rise of the coil can be suppressed.
- This hybrid type capacitor has a small heat capacity, but is smaller than an electrolytic capacitor. Since the temperature rise of the smoothing capacitor is reduced, the size of the rotating electrical machine can be reduced by using a hybrid type capacitor.
- FIG. 40 is an explanatory diagram of a rotary electric machine according to Embodiment 19 of the present invention.
- the basic structure is the same as in the first embodiment, and both the smoothing capacitor 19 and the noise reduction coil 11 are arranged on the rear side of the control board 13.
- the armature winding 15b and the switching element 12 of the rotating electrical machine 10 generate heat because current is supplied, and the heat sink 20 absorbs heat generation because the heat sink 20 is in contact with the switching element 12.
- a flat heat insulating material 35 is provided between the control board 13 and the circuit wiring member 26 b so as to be substantially parallel to the control board 13.
- the armature winding 15b, the switching element 12, the heat sink 20, and the like are rotated from the viewpoint of preventing the smoothing capacitor 19 and the noise reduction coil 11 from failing in order to raise the temperatures of the smoothing capacitor 19 and the noise reduction coil 11 that are close to each other. It is necessary to suppress the current supplied to the electric machine 10. When the temperature rises, the torque of the rotating electrical machine 10 decreases and the reliability of the smoothing capacitor 19 decreases.
- the smoothing capacitor 19 and the noise reduction coil 11 are both installed on the circuit wiring member 26b disposed on the rear side of the control board 13.
- the heat insulating material 35 is provided between the control board 13 and the circuit wiring member 26 b so as to be substantially parallel to the control board 13. Heat transmitted from the armature winding 15b, the switching element 12, the heat sink 20, and the like to the smoothing capacitor 19 and the noise reduction coil 11 is reduced. As a result, the temperature rise of the smoothing capacitor 19 and the noise reduction coil 11 can be suppressed, the torque reduction of the rotating electrical machine can be suppressed, and the reliability of the smoothing capacitor 19 can be improved. Since the heat insulating material 35 is disposed between the circuit wiring member 26b and the control board 13 so as to be substantially parallel to the control board 13, the torque is reduced without increasing the axial size of the rotating electrical machine. And the reliability of the smoothing capacitor can be improved.
- FIG. FIG. 41 is an explanatory diagram of a rotary electric machine according to Embodiment 20 of the present invention.
- the heat insulating material 35 is provided between the control board 13 and the circuit wiring member 26b.
- the flat heat insulating material 35 is disposed on the rear side of the circuit wiring member 26b. Since the heat insulating material 35 is provided under the smoothing capacitor 19 and the noise reducing coil 11, the same effect as in the previous embodiment can be obtained.
- the heat insulating material 35 may be in contact with the circuit wiring member 26b, or may be a heat insulating member provided on the control board 13 or the circuit wiring member 26b.
- the effect that the number of parts can be reduced or the axial space of the rotating electrical machine can be reduced by reducing the axial space can be obtained. Even when the size and position of the heat insulating material are different, the same effect can be obtained if the heat insulating material is arranged so as to be substantially parallel to the control board between the control board and the smoothing capacitor and the noise reduction coil. Needless to say.
- FIG. FIG. 42 is an explanatory diagram of a rotary electric machine according to Embodiment 21 of the present invention.
- a flat heat insulating material 35 is provided between the control board 13, the smoothing capacitor, and the noise reduction coil, and it goes without saying that the same effect as in the previous embodiment can be obtained.
- the circuit wiring member 26 a is one member disposed on the rear side of the heat sink 20 and on the front side of the control board 13.
- the heat insulating material 35 may be in contact with the control board 13 or may be a heat insulating member provided on the control board 13 or the circuit wiring member 26a.
- the effect that the number of parts can be reduced or the axial space of the rotating electrical machine can be reduced by reducing the axial space can be obtained. Even when the size and position of the heat insulating material are different, the same effect can be obtained if the heat insulating material is arranged so as to be substantially parallel to the control board between the control board, the smoothing capacitor, and the noise reduction coil. Needless to say.
- FIG. FIG. 43 is an explanatory diagram of a rotary electric machine according to Embodiment 22 of the present invention.
- the basic structure is the same as in the first embodiment, and both the smoothing capacitor 19 and the noise reduction coil 11 are arranged on the rear side of the control board 13.
- a flat noise blocking member 33 is provided between the control board 13 and the circuit wiring member 26 b so as to be substantially parallel to the control board 13. Since the smoothing capacitor 19 and the noise reduction coil 11 are supplied with current, electromagnetic noise is generated in the surroundings, and magnetic flux is linked to the adjacent rotation sensor 24, so that the angle error of the rotation sensor 24 increases. Further, the control device malfunctions due to the magnetic flux interlinking with the control board 13. These effects increase the vibration and noise of the rotating electrical machine.
- the noise shielding member 33 include a metal plate.
- the smoothing capacitor 19 and the noise reduction coil 11 are both installed on the circuit wiring member 26 b, and the circuit wiring member 26 b is arranged on the rear side of the control board 13. Further, since the noise blocking member 33 is provided between the control board 13 and the circuit wiring member 26b so as to be substantially parallel to the control board 13, the rotation sensor 24 and the control are controlled from the smoothing capacitor 19 and the noise reduction coil 11. The amount of interlinkage that fluxes the substrate 13 is reduced. Therefore, the angle error of the rotation sensor 24 is reduced, and it is possible to prevent the malfunction of the rotating electrical machine and to reduce the vibration and noise of the rotating electrical machine.
- the noise blocking member 33 is disposed between the control board 13 and the circuit wiring member 26b so as to be parallel to the control board, the rotation sensor angle is not increased without increasing the axial size of the rotating electrical machine. Error can be reduced. A malfunction of the control device is prevented, and vibration and noise of the rotating electrical machine are reduced.
- FIG. FIG. 44 is an explanatory diagram of a rotary electric machine according to Embodiment 23 of the present invention.
- the noise shielding member 33 is provided between the control board 13 and the circuit wiring member 26b. As shown in the figure, it goes without saying that the same effect can be obtained even if the noise shielding member 33 is provided on the rear side of the circuit wiring member 26b.
- the noise blocking member 33 may be in contact with the control board 13 or the circuit wiring member 26b.
- the noise blocking member 33 may be a noise shielding member provided on the control board 13 or the circuit wiring member 26b. The effect that the number of parts can be reduced or the axial space of the rotating electrical machine can be reduced by reducing the axial space can be obtained.
- FIG. 45 is an illustration of a rotary electric machine according to Embodiment 24 of the present invention.
- FIG. It goes without saying that the same effect can be obtained even when the noise blocking member 33 is provided between the control board 13 and the smoothing capacitor 19 and the noise reducing coil 11.
- the circuit wiring member 26 a is one member disposed on the rear side of the heat sink 20 and on the front side of the control board 13. Even when the size and position of the noise blocking member are different, the same effect can be obtained if the noise blocking member is arranged so as to be substantially parallel to the control substrate between the control substrate, the smoothing capacitor, and the noise reduction coil. It is done.
- FIG. FIG. 46 is an explanatory diagram of a rotary electric machine according to Embodiment 25 of the present invention.
- the basic structure is the same as in the first embodiment.
- both the smoothing capacitor 19 and the noise reduction coil 11 are arranged on the rear side of the control board 13 and the circuit wiring member 26 b, and the noise shielding member 33 is arranged around the noise reduction coil 11.
- the smoothing capacitor 19 and the noise reduction coil 11 are both arranged on the rear side of the control board 13, magnetic coupling between the smoothing capacitor 19 and the normal mode coil 11b occurs.
- the noise shielding member 33 is inserted between the smoothing capacitor 19 and the normal mode coil 11b, the magnetic coupling between the smoothing capacitor 19 and the normal mode coil 11b arranged in close proximity is reduced. It becomes possible. As a result, malfunction of the control device can be prevented, or the rotating electrical machine 10 can be driven smoothly, and vibration and noise of the rotating electrical machine are reduced.
- the noise reduction coil 11 and the smoothing capacitor 19 are arranged on the rear side of the control board 13, but the noise reduction coil 11 and the smoothing capacitor 19 are arranged on the rear side of the control board 13. It goes without saying that the same effect can be obtained even if at least one of the above is arranged.
- an example in which the noise shielding member 33 is inserted between the smoothing capacitor 19 and the normal mode coil 11b has been shown. However, even when the noise shielding member 33 is inserted between the smoothing capacitor 19 and the common mode coil 11a, they are arranged close to each other. The magnetic coupling between the smoothing capacitor 19 and the common mode coil 11a can be reduced, and the same effect can be obtained.
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Abstract
Description
図1はこの発明の実施の形態に係る自動車の電動パワーステアリング装置100の説明図である。制御装置4とモータ部5は連結されて一体化し、回転電機10をなしている。回転電機10の制御装置4にはバッテリーやオルタネータからコネクタ3aを介して電源が供給されている。回転電機10のモータ部5は固定子15と回転子16を備えている。運転者はステアリングホイール1aを操舵すると、そのトルクがステアリングシャフト1bを介してシャフト1cに伝達される。このときトルクセンサ2が検出したトルク(トルク信号)は電気信号に変換されコネクタ3bを介して回転電機10の制御装置4に伝達される。一方、車速などの自動車情報は電気信号に変換され、コネクタ3cを介して回転電機10の制御装置4に伝達される。
MOS-FET12bの一端は、シャント抵抗12dを介して車両の接地電位部に接続されている。MOS-FET12aとMOS-FET12bの接続点は、3相ブリッジ回路のU相交流側端子となる。MOS-FET12cは、一端がU相交流側端子に接続され、他端が電機子巻線15bのU相端子に接続されている。W相のスイッチング素子12とV相のスイッチング素子12も同様の構成となっている。
図21Aと図21Bはこの発明の実施の形態2に係る回転電機の説明図である。基本的なヒートシンクの構造は実施の形態1と同様である。図に示すように3つのモータ端子21は一つの電気配線貫通穴20dを通るように構成してある。ヒートシンク20にはリア側に小電流用部品を有する制御基板13が隣接して設けられている。このとき、ヒートシンク20の穴の数を少なくできるためヒートシンクの体積を向上でき、ヒートシンクの熱容量を向上できるためスイッチング素子の冷却性が向上する。なお、モータ端子が電気配線貫通穴を貫通するものとしたが、他の回転電機と制御装置との間の信号線やケーブル等の電気配線が貫通する場合でも同様の効果が得られることは言うまでもない。
図22はこの発明の実施の形態3に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すように電機子巻線の3相結線をリング状の結線板25を介してモータ端子21に接続する構造としている。固定子鉄心15aの電機子巻線は互いに接続され3相結線を構成している。結線板25はモータ端子21と電機子巻線15bの間に配置されている。
図23Aと図23Bはこの発明の実施の形態4に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すように、スイッチング素子12は回路配線部材26aと一体で構成されている。回路配線部材26aは、バスバー26c、フレーム26d、電源端子27a、回路端子27bなどから構成されている。フレーム26dは樹脂などの絶縁部材で構成され、バスバー26cなどを保持している。回路配線部材26aのバスバー26cは電源端子27aと接続されている。
図24はこの発明の実施の形態5に係る回転電機の説明図である。基本的な構造は実施の形態1と同様であるので、図を用いてセンサ用永久磁石23について補足説明する。センサ用永久磁石23はヒートシンクからリア側に突出しているものとしたが、ヒートシンクに少なくとも一部が沈下し、埋設されているようにしても同様の効果が得られる。ここではヒートシンク20にはリア側凹部20jが形成されている。センサ用永久磁石23はリア側凹部20jに沈下し、埋設されている。
図25はこの発明の実施の形態6に係る回転電機の説明図である。基本的な構造は実施の形態1と同様であるので、図を用いてハウジングについて補足説明する。モータフレーム22aは回転電機の前面部に設けられたフロント側ハウジング22bと一体となっている。このとき、ハウジングとモータフレームの間の熱抵抗が低下するためモータフレームの冷却性が向上し、またシャフトとモータフレームの同軸度が向上し、回転電機の振動を低減できる。
図26はこの発明の実施の形態7に係る回転電機の説明図である。基本的な構造は実施の形態1と同様であるので、図を用いてモータフレームについて補足説明する。モータフレーム22aはヒートシンク20と一体となっている。このとき、ヒートシンク20とモータフレーム22aの間の熱抵抗が低下するためスイッチング素子12の冷却性が向上する。また回転軸16bとモータフレーム22aの同軸度が向上し、回転電機10の振動を低減できる。
図27はこの発明の実施の形態8に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。ここではノイズ低減用コイル11の周囲にノイズ遮蔽部材33を配置している。図にはコモンモードコイル11aとノーマルモードコイル11bとの間にノイズ遮蔽部材33を挿入した例が示されている。このようにすることで、近接して配置されるコモンモードコイル11aとノーマルモードコイル11bとの磁気結合を低減することが可能となる。制御装置の誤作動を防止したり、回転電機10を滑らかに駆動することができ、回転電機の振動や騒音が低減する。ノイズ遮蔽部材33の例としては、金属板などが挙げられる。ノイズ低減用コイル11および平滑コンデンサ19は制御基板13よりもリア側に配置されているものとしている。制御基板13よりもリア側にノイズ低減用コイル11と平滑コンデンサ19の少なくともいずれか1方が配置されていても同様の効果が得られることは言うまでもない。
図28はこの発明の実施の形態9に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すように平滑コンデンサ19とコモンモードコイル11aは制御基板13よりもリア側に配置されている。ノーマルモードコイル11bは回路配線部材26aに配設されており、制御基板13と一部軸方向に重なっている。制御基板13と一部軸方向に重なっているのはノーマルモードコイル11bとしているが、平滑コンデンサ19またはコモンモードコイル11aとしてもよいのは言うまでもない。また、ノイズ低減用コイル11はコモンモードコイル11aとノーマルモードコイル11bから構成されるものとしている。どちらか片方のみで構成されていても同様の効果が得られることは言うまでもない。
図29はこの発明の実施の形態10に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すようにヒートシンク20は制御基板13にまで突出したリア側突出部20eを有している。リング状または柱状のリア側突出部20eは、グリス等を介して制御基板13の発熱部品(マイクロコンピュータ13a、FET駆動回路13bなど)の少なくとも1つと接触しているか、あるいは発熱部品と近接配置されている。従って、制御基板13の発熱部品の放熱と冷却性を向上することができる。また、ノイズ低減用コイル11と平滑コンデンサ19は回路配線部材26bよりもリア側に配設されているので、リア側のベアリング17bと制御基板13の間の距離が小さくなり、結果、リア側突出部20eを短くすることができ、回転電機を小型軽量化できる。
図30Aと図30Bはこの発明の実施の形態11に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すようにリア側のベアリング17bとヒートシンク20の間に断熱材20fが挿入されている。このようにすることで、スイッチング素子12の発熱によりヒートシンク20の温度が上昇した際に、リア側のベアリング17bの温度上昇を抑制することができる。よって、潤滑材の劣化などを防ぐことができ、ベアリングの寿命を長くすることができる。なお、断熱材20fを挿入しなくてもヒートシンク20との間の熱抵抗を高くする構造としても同等の効果が得られることは言うまでもない。
図31Aと図31Bはここの発明の実施の形態12に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すようにヒートシンク20は結線板25と軸方向に重なる位置でフロント側に突出したフロント側突出部20gを備えている。よって、ヒートシンクの熱容量が向上でき、スイッチング素子の冷却性が向上できる。また、リア側のベアリングはフロント側突出部20gに配置されている。よって、リア側のベアリング間の距離が縮小でき、回転電機の振動を抑制できる。また、ヒートシンクは回転電機のリア側に突出する結線板25を収納するリング状フロント側凹部20iを備えている。よって、回転電機を小型化できる。
図32Aと図32Bはここの発明の実施の形態13に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すようにヒートシンク20は電機子巻線のリア側のコイルエンドと軸方向に重なる位置でフロント側に突出したフロント側突出部20gを備えている。よって、ヒートシンクの熱容量が向上でき、スイッチング素子の冷却性が向上できる。また、リア側のベアリングはフロント側突出部20gに配置されている。よって、リア側のベアリング間の距離が縮小でき、回転電機の振動を抑制できる。また、ヒートシンクは回転電機のリア側に突出する電機子巻線のコイルエンドを収納するリング状フロント側凹部20iを備えている。よって、回転電機を小型化できる。
図33Aと図33Bはこの発明の実施の形態14に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。図に示すように回転子16には回転子鉄心凹部16gに軸方向に重なる位置でフロント側に突出している突出部20kを設けている。よって、ヒートシンク20の熱容量が向上でき、スイッチング素子12の冷却性が向上できる。また、リア側のベアリング17bは突出部20kに配置されている。よって、リア側のベアリング間の距離がさらに縮小でき、回転電機の振動を抑制できる。また、ヒートシンク20は回転電機のリア側に突出する電機子巻線のコイルエンドを収納するリング状フロント側凹部20iを備えている。よって、回転電機を小型化できる。
図34はこの発明の実施の形態15に係る回転電機の説明図である。基本的な構造は実施の形態1と同様であるので、図を用いてヒートシンクについて補足説明する。スイッチング素子12はヒートシンク20に接着されている。リア側のベアリング17bはリア側ハウジング34に支持されている。このように、リア側ハウジング34を設けたので部品数が増えるもののリア側のベアリング17bの温度上昇が抑制されるため、回転電機が長寿命化する。
図35はこの発明の実施の形態16に係る回転電機の説明図である。回路配線部材26aは、ヒートシンク20よりもリア側かつ制御基板13よりもフロント側に配置されている1つの部材である。回路配線部材26aは、バスバー26c、コモンモードコイル11a、ノーマルモードコイル11b、平滑コンデンサ19、回路端子(入力端子)27bなどが溶接またはプレスフィット、はんだなどで電気的に接続されている。ベアリング17bが挿入される位置よりもリア側にノイズ低減用コイル11、平滑コンデンサ19、回路配線部材26aが配置されているため、これらの部品が回転電機の内部に脱落した際の回転電機の故障を防ぐことが可能となる。ヒートシンク20に搭載されたスイッチング素子12とノイズ低減用コイル11の間には回路配線部材26aを設けている。スイッチング素子12のノイズが回路配線部材26aのバスバー26cにより遮蔽され、スイッチング素子とノイズ低減用コイル11の間の磁気結合を低減することが可能となる。
図38はこの発明の実施の形態17に係る回転電機の説明図である。ヒートシンク20および制御基板13よりもリア側に回路配線部材26bが配置されている。回路配線部材26bは、バスバー26c、コモンモードコイル11a、ノーマルモードコイル11b、平滑コンデンサ19、電源端子27a、回路端子(入力端子)27bなどが溶接またはプレスフィット、はんだなどで電気的に接続されている。ベアリング17bが挿入される位置よりもリア側には、ノイズ低減用コイル11と平滑コンデンサ19を搭載している回路配線部材26bが配置されている。これらの部品が回転電機の内部に脱落した際に、回転電機の故障を防ぐことが可能である。スイッチング素子12と制御基板13の間に回路配線部材が設けられないため、軸長あたりのヒートシンク20の体積を確保できるうえに、ヒートシンク20の軸方向のサイズを小型化しながらも熱容量が向上する。さらにリア側のベアリング17bと制御基板13の間に回路配線部材が配置されないため、リア側のベアリング17bと制御基板13の間の距離が小さくなる。結果、回転電機10のサイズが小型化し、さらに回転電機10を軽量化できる。複数の回路端子27bは回路配線部材26bまで延在し、平滑コンデンサ19およびノイズ低減用コイル11と接続されている。
図40はこの発明の実施の形態19に係る回転電機の説明図である。基本的な構造は実施の形態1と同様であり、平滑コンデンサ19とノイズ低減用コイル11がともに制御基板13のリア側に配置されている。回転電機10の電機子巻線15bとスイッチング素子12は、電流が供給されるので発熱し、ヒートシンク20はスイッチング素子12と接触しているので発熱を吸収する。本実施の形態では、制御基板13と回路配線部材26bの間には、制御基板13とほぼ平行になるように平板状の断熱材35が設けられている。電機子巻線15b、スイッチング素子12、ヒートシンク20などは、近接する平滑コンデンサ19およびノイズ低減用コイル11の温度を上昇させるため、平滑コンデンサ19やノイズ低減用コイル11の故障を防ぐ観点から、回転電機10に供給する電流を抑制する必要がある。温度が上昇すると、回転電機10のトルクが低下し、平滑コンデンサ19の信頼性が低下する。
図41はこの発明の実施の形態20に係る回転電機の説明図である。前実施の形態では、断熱材35を制御基板13と回路配線部材26bの間に設けていた。本実施の形態では、同図に示すように、平板状の断熱材35を回路配線部材26bよりもリア側に配設している。断熱材35が平滑コンデンサ19とノイズ低減用コイル11の足下に設けられているので、前実施の形態と同様の効果が得られる。
図42はこの発明の実施の形態21に係る回転電機の説明図である。本実施の形態では、平板状の断熱材35を制御基板13と平滑コンデンサおよびノイズ低減用コイルの間に設けた構成としており、前実施の形態と同様の効果が得られることはいうまでもない。回路配線部材26aは、ヒートシンク20よりもリア側かつ制御基板13よりもフロント側に配置されている1つの部材である。
図43はこの発明の実施の形態22に係る回転電機の説明図である。基本的な構造は実施の形態1と同様であり、平滑コンデンサ19とノイズ低減用コイル11はともに制御基板13のリア側に配置されている。本実施の形態では、制御基板13と回路配線部材26bの間に、制御基板13とほぼ平行になるように平板状のノイズ遮断部材33が設けられている。平滑コンデンサ19とノイズ低減用コイル11は電流が供給されるため周囲に電磁ノイズを発生し、近接する回転センサ24に磁束が鎖交することで、回転センサ24の角度誤差が増加する。また、制御基板13に磁束が鎖交することで、制御装置が誤作動する。これらの影響により、回転電機の振動と騒音が大きくなる。ノイズ遮蔽部材33の例としては、金属板などが挙げられる。
図44はこの発明の実施の形態23に係る回転電機の説明図である。前実施の形態では、ノイズ遮蔽部材33を制御基板13と回路配線部材26bの間に設けた。同図に示すように、ノイズ遮蔽部材33を回路配線部材26bのリア側に設けても同様の効果が得られることはいうまでもない。ノイズ遮断部材33は、制御基板13または回路配線部材26bと接触していてもよい。また、ノイズ遮断部材33は、制御基板13または回路配線部材26bに設けられているノイズ遮蔽部材であってもよい。部品点数を削減したり、軸方向のスペースを削減して回転電機の軸方向のサイズを低減できるといった効果が得られる。
図45この発明の実施の形態24に係る回転電機の説明図である。ノイズ遮断部材33は制御基板13と平滑コンデンサ19およびノイズ低減用コイル11の間に設けた構成としても同様の効果が得られることはいうまでもない。同図に示すように、回路配線部材26aは、ヒートシンク20よりもリア側かつ制御基板13よりもフロント側に配置されている1つの部材である。ノイズ遮断部材のサイズや位置が異なる場合においても、制御基板と平滑コンデンサ、ノイズ低減用コイルの間に制御基板とほぼ平行となるようにノイズ遮断部材を配置した構成とすれば同様の効果が得られる。
図46はこの発明の実施の形態25に係る回転電機の説明図である。基本的な構造は実施の形態1と同様である。ここでは平滑コンデンサ19とノイズ低減用コイル11がともに制御基板13および回路配線部材26bのリア側に配置されており、ノイズ低減用コイル11の周囲にノイズ遮蔽部材33を配置している。平滑コンデンサ19とノイズ低減用コイル11がともに制御基板13のリア側に配置されている構成では、平滑コンデンサ19とノーマルモードコイル11bとの磁気結合が発生する。本実施の形態では、平滑コンデンサ19とノーマルモードコイル11bとの間にノイズ遮蔽部材33が挿入されているため、近接して配置される平滑コンデンサ19とノーマルモードコイル11bとの磁気結合を低減することが可能となる。その結果、制御装置の誤作動を防止したり、回転電機10を滑らかに駆動することができ、回転電機の振動や騒音が低減する。
Claims (35)
- センサ用永久磁石が回転軸のリア側に取り付けられている回転子と、
固定子鉄心と電機子巻線を有する固定子と、
前記回転軸のフロント側を支持する第1ベアリングが固定されているフロント側ハウジングと、
前記フロント側ハウジングと結合されていて、前記回転子と前記固定子を収容するモータフレームと、
前記回転軸のリア側を支持する第2ベアリングが固定されていて、複数のスイッチング素子を搭載しているヒートシンクと、
前記ヒートシンクよりもリア側に配設されていて、回転センサとマイクロコンピュータと駆動回路が実装されている制御基板と、
前記複数のスイッチング素子に接続されている平滑コンデンサと、
前記複数のスイッチング素子に接続されているノイズ低減用コイルと、を備え、
前記回転センサは前記センサ用永久磁石と対向しており、前記マイクロコンピュータは前記回転センサからの信号に基いて前記駆動回路を制御して前記複数のスイッチング素子を駆動し、前記平滑コンデンサと前記ノイズ低減用コイルの少なくとも何れか一方は前記制御基板よりもリア側に配設されていることを特徴とする制御装置付き回転電機。 - センサ用永久磁石が回転軸のリア側に取り付けられている回転子と、
電機子巻線に接続された複数のモータ端子を有する固定子と、
前記回転軸のフロント側を支持する第1ベアリングが固定されているフロント側ハウジングと、
前記フロント側ハウジングと結合されていて、前記回転子と前記固定子を収容するモータフレームと、
前記回転軸のリア側を支持する第2ベアリングが固定されていて、前記モータ端子が貫通する第1貫通穴が形成されかつ複数のスイッチング素子を搭載しているヒートシンクと、前記ヒートシンクよりもリア側に配設されており、複数の回路端子が実装されていて、中央に前記回転軸が貫通する第2貫通穴を有する第1回路配線部材と、
複数の第3貫通穴を有し、前記第1回路配線部材よりもリア側に配設されていて、回転センサとマイクロコンピュータと駆動回路が実装されている制御基板と、
前記制御基板よりもリア側に配設されており、平滑コンデンサおよびノイズ低減用コイルが実装されている第2回路配線部材と、
前記第1回路配線部材と前記制御基板と前記第2回路配線部材を収容する制御装置ケースと、を備え、
前記回転センサは前記センサ用永久磁石と対向しており、前記マイクロコンピュータは前記回転センサからの信号に基いて前記駆動回路を制御して前記複数のスイッチング素子を駆動し、
前記複数の回路端子は個々に前記複数の第3貫通穴を通過して前記第2回路配線部材まで延在し、前記平滑コンデンサおよび前記ノイズ低減用コイルと接続されていることを特徴とする制御装置付き回転電機。 - センサ用永久磁石が回転軸のリア側に取り付けられている回転子と、
電機子巻線に接続された複数のモータ端子を有する固定子と、
前記回転軸のフロント側を支持する第1ベアリングが固定されているフロント側ハウジングと、
前記フロント側ハウジングと結合されていて、前記回転子と前記固定子を収容するモータフレームと、
前記回転軸のリア側を支持する第2ベアリングが固定されていて、前記モータ端子が貫通する第1貫通穴が形成されかつ複数のスイッチング素子を搭載しているヒートシンクと、前記ヒートシンクよりもリア側に配設されており、複数の回路端子が実装されていて、中央に前記回転軸が貫通する第2貫通穴を有する回路配線部材と、
複数の第3貫通穴を有し、前記回路配線部材よりもリア側に配設されており、回転センサとマイクロコンピュータと駆動回路が実装されている制御基板と、
前記回路配線部材と前記制御基板を収容する制御装置ケースと、を備え、
前記回転センサは前記センサ用永久磁石と対向しており、前記マイクロコンピュータは前記回転センサからの信号に基いて前記駆動回路を制御して前記複数のスイッチング素子を駆動し、
前記複数の回路端子は個々に前記複数の第3貫通穴を通過して前記制御基板のリア側まで延在し、平滑コンデンサおよびノイズ低減用コイルと接続されていることを特徴とする制御装置付き回転電機。 - 前記ヒートシンクは前記モータフレームと嵌合されていることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記第1貫通穴は前記ヒートシンクに複数個形成されていて、前記複数のモータ端子は個々にこの複数個の第1貫通穴を貫通していることを特徴とする請求項2または3に記載の制御装置付き回転電機。
- 前記第1貫通穴は前記ヒートシンクに単数個形成されていて、前記複数のモータ端子はこの単数個の第1貫通穴を貫通していることを特徴とする請求項2または3に記載の制御装置付き回転電機。
- 前記複数のモータ端子と前記第1回路配線部材の配線を仲介するリング状の結線板を備えていることを特徴とする請求項2に記載の制御装置付き回転電機。
- 前記複数のスイッチング素子は前記第1回路配線部材に密着していることを特徴とする請求項2に記載の制御装置付き回転電機。
- 前記ヒートシンクはリア側に凹部が形成されていることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記モータフレームは前記フロント側ハウジングと一体物であることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記モータフレームは前記ヒートシンクと一体物であることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記ノイズ低減用コイルの周囲にノイズ遮蔽部材を備えていることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記第1回路配線部材にノーマルモードコイルが実装されていることを特徴とする請求項2に記載の制御装置付き回転電機。
- 前記ヒートシンクはリア側に突出部を有していることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記第2ベアリングは断熱材を介在して前記ヒートシンクに固定されていることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記ヒートシンクはフロント側にリング状の凹部が形成されていて、前記リング状の結線板は前記リング状の凹部と対向していることを特徴とする請求項7に記載の制御装置付き回転電機。
- 前記ヒートシンクはフロント側にリング状の凹部が形成されていて、前記固定子の電機子巻線は前記リング状の凹部と対向していることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記ヒートシンクはフロント側に突出部が形成されていることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記回転子は回転子鉄心のリア側に凹部を有し、前記ヒートシンクの突出部は前記回転子の凹部に収まっていることを特徴とする請求項18に記載の制御装置付き回転電機。
- 前記ヒートシンクは、前記第2ベアリングの外径よりも小さく、前記第2ベアリングの内径よりも大きいシャフト貫通穴が、前記第2ベアリングよりもリア側に形成されていることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記回転軸は、フロント側とリア側の先端にシャフト保持部を有することを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記モータフレームおよび前記ヒートシンクが同じ金属材料からなることを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- 前記モータフレームおよび前記ヒートシンクがアルミニウム合金からなることを特徴とする請求項22に記載の制御装置付き回転電機。
- 前記センサ用永久磁石の外径は、前記回転軸の外径よりも大きいことを特徴とする請求項1から3のいずれか1項に記載の制御装置付き回転電機。
- センサ用永久磁石が回転軸のリア側に取り付けられている回転子と、
電機子巻線に接続された複数のモータ端子を有する固定子と、
前記回転軸のフロント側を支持する第1ベアリングが固定されているフロント側ハウジングと、
前記フロント側ハウジングと結合されていて、前記回転子と前記固定子を収容するモータフレームと、
前記回転軸のリア側を支持する第2ベアリングが固定されていて、前記モータ端子が貫通する貫通穴が形成されかつ複数のスイッチング素子を搭載しているヒートシンクと、
複数の回路端子が実装され、前記ヒートシンクよりもリア側に配設されていて、回転センサとマイクロコンピュータと駆動回路が実装されている制御基板と、
前記制御基板よりもリア側に配設されており、平滑コンデンサおよびノイズ低減用コイルを搭載している回路配線部材と、
前記制御基板と前記回路配線部材を収容する制御装置ケースと、を備え、
前記回転センサは前記センサ用永久磁石と対向しており、前記マイクロコンピュータは前記回転センサからの信号に基いて前記駆動回路を制御して前記複数のスイッチング素子を駆動し、
前記複数の回路端子は前記回路配線部材まで延在し、前記平滑コンデンサおよび前記ノイズ低減用コイルと接続されていることを特徴とする制御装置付き回転電機。 - 前記制御装置ケースは、前記ヒートシンクに接続された絶縁性の第1のケース部材と、前記第1のケース部材よりもリア側に設置された金属製の第2のケース部材を有し、前記平滑コンデンサは前記第2のケース部材と接触していることを特徴とする請求項2、3、25のいずれか1項に記載の制御装置付き回転電機。
- 前記制御基板よりもリア側に設置された断熱材またはノイズ遮断部材を備えていることを特徴とする請求項1、3、25のいずれか1項に記載の制御装置付き回転電機。
- 前記制御基板と前記第2回路配線部材の間に設置された断熱材またはノイズ遮断部材を備えていることを特徴とする請求項2に記載の制御装置付き回転電機。
- 前記第2回路配線部材よりもリア側に設置された断熱材またはノイズ遮断部材を備えていることを特徴とする請求項2に記載の制御装置付き回転電機。
- 前記平滑コンデンサと前記ノイズ低減用コイルの間に設置されたノイズ遮断部材を備えていることを特徴とする請求項1、2、3、25のいずれか1項に記載の制御装置付き回転電機。
- ステアリングホイールに連結されたステアリングシャフトと、
請求項1から30のいずれか1項に記載の制御装置付き回転電機と、
前記制御装置付き回転電機で発生した回転トルクを減速するギヤボックスと、
前記ステアリングシャフトに伝達されたトルクを検出するトルクセンサとを備え、
前記トルクセンサが検出した信号は前記制御装置付き回転電機に入力されることを特徴とする電動パワーステアリング装置。 - 回転子鉄心に回転軸を圧入する第1工程と、
第1ベアリングが固定されたフロント側ハウジングを回転子鉄心の回転軸に圧入する第2工程と、
ヒートシンクに第2ベアリングおよび複数のスイッチング素子を固定する第3工程と、
固定子を有するモータフレームとヒートシンクを固定する第4工程と、
回転軸のリア側に第2ベアリングを挿入する第5工程と、
モータフレームとフロント側ハウジングを固定する第6工程と、
回転軸のリア側にセンサ用永久磁石を固定する第7工程と、
回転センサとマイクロコンピュータと駆動回路が実装されている制御基板を固定する第8工程と、を備え、
前記第1工程から前記第6工程を実施した後に前記第7工程または前記第8工程を実施することを特徴とする制御装置付き回転電機の製造方法。 - 前記第7工程を実施してから前記第8工程を実施することを特徴とする請求項32に記載の制御装置付き回転電機の製造方法。
- 前記第8工程を実施してから前記第7工程を実施することを特徴とする請求項32に記載の制御装置付き回転電機の製造方法。
- 前記第3工程を実施してから前記第4工程を実施することを特徴とする請求項32に記載の制御装置付き回転電機の製造方法。
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DE112014006362T5 (de) | 2016-11-17 |
CN105993115A (zh) | 2016-10-05 |
CN105993115B (zh) | 2018-06-19 |
JPWO2015122069A1 (ja) | 2017-03-30 |
DE112014006362B4 (de) | 2022-08-18 |
US10236750B2 (en) | 2019-03-19 |
JP6184531B2 (ja) | 2017-08-23 |
US20170008554A1 (en) | 2017-01-12 |
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