Electric power steering apparatus

• US 7,021,418 B2
• Filed: 05/10/2004
• Issued: 04/04/2006
• Est. Priority Date: 02/02/2004
• Status: Active Grant

• Current Assignee: Mitsubishi Electric Corporation
• Original Assignee: Mitsubishi Denki Kabushiki Kaisha (Mitsubishi Electric Corporation)
• Inventors: Fujimoto, Tadayuki, Tominaga, Tsutomu
• Primary Examiner(s): WINNER, TONY H
• Application Number:
  US10/841,494
• Publication Number:
  US 20050167183A1
• Time in Patent Office: 694 Days
• Field of Search: 180/444, 180/443, 310/89, 310/91, 310/67.R, 310/68.B, 310/68.R, 310/64, 743/88.PS
• US Class Current: 180/444
• CPC Class Codes: B62D 5/0406 including housing for electronic control unit
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02K 7/1166 comprising worm and worm-wheel structural association with bearings specially adapted for worm gear drives H02K7/081
• CPC Class Codes: H05K 7/14322 wherein the control and power circuits of a power converter are arranged within the same casing
• CPC Class Codes: H05K 7/209 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20909 takes precedence

Abstract

An electric power steering apparatus can improve heat dissipation of a power board. A heat sink is mounted on the power board in surface contact therewith, on which power board there is mounted a bridge circuit including a plurality of semiconductor switching elements for switching an electric current supplied to an electric motor in accordance with torque assisting a steering wheel. The heat sink has a plurality of protrusions formed on a surface thereof at a side opposite to the power board.

Claims

1. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board,

wherein said capacitor is fixedly attached to said housing by means of an adhesive, and

wherein said housing has a beam for reinforcement formed in the neighborhood of said capacitor, and said capacitor is fixedly attached to said beam.

2. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board,

wherein said power connector and said signal connector unit are disposed in an axial direction of said electric motor at a side opposite to said motor terminals with said connection member interposed therebetween.

3. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board,

wherein said motor terminals are formed on one end of said conductive plate, and a switch for turning on and off the motor current supplied to said electric motor is disposed on an electric path including said conductive plate connected to at least one of said motor terminals, said switch being held by said housing.

4. The electric power steering apparatus as set forth in claim 3, wherein said housing has a switch-holding portion made of said insulation resin, and said switch has a terminal electrically connected with said conductive plate and is held by said housing with its terminal clamped by said conductive plate and said switch-holding portion of said housing.

5. The electric power steering apparatus as set forth in claim 4, wherein said switch-holding portion is formed with a convex portion protruding toward its terminal side.

6. The electric power steering apparatus as set forth in claim 4, wherein said switch-holding portion is formed with a low-rigidity portion.

7. The electric power steering apparatus as set forth in claim 6, wherein said low-rigidity portion is a portion of a narrow width provided by an elongated hole formed in an insulation resin portion of said housing in the neighborhood of said terminal of said switch.

8. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board, and

wherein said power connector has terminals formed at one end of said conductive plate, and a coil for preventing noise generated upon switching operation of said bridge circuit from flowing out to the outside is disposed on electric paths including said conductive plate, said coil being held by said housing.

9. The electric power steering apparatus as set forth in claim 8, wherein said coil comprises a core of a T-shaped cross-sectional configuration having a large-diameter portion and a small-diameter portion, and a coil portion wound around said small-diameter portion, and said housing has a holder portion into which said large-diameter portion of said core is fitted.

10. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board, and

wherein said housing is formed at a side surface thereof with an engaging portion that has cut portions at opposite ends thereof, respectively, and a metal casing covering said control board, said housing and said power board to form an electromagnetic shield is fixedly secured to said housing by being inserted into said cut portions.

11. The electric power steering apparatus as set forth in claim 10, wherein each of said cut portions has a sloped surface with its opening width increasing gradually from an inner side to an outer side, and said casing has engagement portions formed at its side near said heat sink, said engagement portions being elastically engaged with said sloped surfaces, respectively.

12. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board, and

wherein said heat sink is formed with an opening through which said motor terminals are exposed to the outside, and a cap molded of an insulation resin and having through holes through which said motor terminals can extend is inserted into said opening, and said cap has its one end which is extended through said opening to be engaged with said housing.

13. The electric power steering apparatus as set forth in claim 12, wherein said cap is formed with a flange which is clamped between said heat sink and said electric motor.

14. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board, and

wherein said control board is engaged by an engaging member formed on said housing at its opening end, and said engaging member has a fallout-preventing portion formed in a fallout direction of said control board for preventing fallout of said control board, and a positioning portion for positioning said control board in its surface direction.

15. The electric power steering apparatus as set forth in claim 14, wherein said fallout-preventing portion and said positioning portion are disposed adjacent to each other.

16. An electric power steering apparatus including an electric motor for generating assist torque to a steering wheel of a vehicle, and a control unit for controlling the driving of said electric motor,

said control unit comprising:

a power board having a bridge circuit mounted thereon which includes a plurality of semiconductor switching elements for switching an electric current supplied to said electric motor in accordance with the torque assisting the operation of said steering wheel;

a capacitor mounted on said power board for absorbing ripples of the electric current;

a control board at least having a microcomputer mounted thereon for generating a drive signal to control said bridge circuit based on steering torque of said steering wheel;

a power connector electrically connected to a battery of the vehicle;

a signal connector unit to and from which signals are input and output through external wiring;

motor terminals electrically connected to said electric motor;

a housing having a conductive plate constituting a wiring pattern and said motor terminals insert-molded of an insulation resin;

a connection member mounted on said power board and having a plurality of terminals built therein for electrically connecting said power board, said housing and said control board to one another; and

a heat sink disposed on said power board in surface contact therewith;

wherein said heat sink has a plurality of protrusions formed on its surface at a side opposite to said power board, and

wherein said housing is formed, on its side wall parallel to a row of terminals of said connection member, with a concave portion into which a convex portion of said signal connector unit is fitted.

17. The electric power steering apparatus as set forth in claim 16, wherein said convex portion is formed with an engagement protrusion, and said engagement protrusion is fitted into an engagement groove that is formed in said concave portion and has a width in a thickness direction of said side wall increasing from a bottom portion toward an insertion opening.