Actuator Connector Axial Relocation Radial Dimension Reduction
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Solution Overview
Problem
Conventional electric power-steering apparatus motors have increased radial dimensions due to the integral connector placement, leading to reduced installation freedom and increased interference with vehicle-mounted parts during mounting.
Innovation Solution
The connector portion is relocated to the first axial end of the actuator, with an extended portion and flange structure that reduces radial dimensions, allowing for a more compact design and minimizing interference with neighboring parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector portion is disposed integrally on the terminal carrier positioned radially outside the housing, then the connector can be easily integrated with the terminal carrier, but the radial dimensions of the motor are increased
Solution Approach 1:
The connector portion is repositioned from a radial arrangement to an axial arrangement, changing the spatial dimension in which the connector is disposed. Specifically, the connector is now positioned at the first axial end of the actuator, extending axially alongside the outer circumferential surface of the actuator housing, which eliminates the increase in radial dimensions while maintaining integration capability
2Ease of operation
If the connector portion is positioned radially outside the housing, then the connector can be easily accessed for connection, but interference with vehicle-mounted parts in the vicinity of the motor is increased
Solution Approach 1:
The connector portion is relocated from the radial direction to the axial direction, specifically at the first axial end of the actuator. This dimensional change positions the connector in a space that does not interfere with vehicle-mounted parts in the vicinity of the motor, while the extended portion and flange structure ensure the connector remains accessible for electrical connections
3Length of stationary object
If the connector portion is relocated to the first axial end of the actuator, then radial dimensions are reduced and installation freedom is increased, but the structural complexity of the connector assembly is increased
Solution Approach 1:
The extended portion, first flange portion, and connector portion are merged into an integrated connector assembly structure. The extended portion extends axially alongside the actuator housing, the first flange portion extends radially inward from the extended portion, and the connector portion is formed on the first flange portion, creating a unified structure that achieves compact radial dimensions while maintaining structural integrity
Solution Approach 2:
The connector assembly is segmented into distinct functional portions: the extended portion for axial extension, the first flange portion for radial support and mounting, and the connector portion for electrical connection. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural coherence
Data Source
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AI summary
The present invention provides an automotive controlling apparatus that increases installation freedom by disposing a connector portion of an external connection connector at a first axial end of an actuator to reduce radial dimensions and suppress interference with peripheral equipment during mounting to a vehicle. The automotive controlling apparatus according to the present invention includes an external connection connector that includes: an insulating resin molded body in which are formed integrally: a second flange portion that is fixed to a first axial end surface of a first bulging portion of a unit housing; an extended portion that extends from the second flange portion alongside an outer circumferential surface of the actuator housing toward the first axial end; a first flange portion that extends radially inward from a first axial end of the extended portion; and a connector portion that is formed on the first flange portion; and a plurality of electrical conductors that are insert-molded into the insulating resin molded body such that first ends thereof protrude inside the connector portion and second ends thereof protrude into a connection window that is formed on a second bulging portion of a heatsink, the electrical conductors being connected to control portion connecting terminals inside the connection window.