Actuator Control Unit Bus Bar Embedding for Compact Design
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Solution Overview
Problem
The existing actuator control units face challenges in further downsizing due to the structural constraints of embedded bus bars within resin, which limits the space for fluidizing resin and forming connections for flat cables, making it difficult to reduce the mounting area effectively.
Innovation Solution
The actuator control unit design features a bus bar arrangement where part of the bus bar is embedded within a circuit mounting case made of resin and partially exposed on the outer surface, allowing for reduced thickness and area usage, with intersecting bus bars and insulating projection portions to manage conductive foreign matter and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bus bar is completely embedded in the resin, then the insulating performance is improved, but the space for forming connections and fluidizing resin is reduced
Solution Approach 1:
The bus bar is extracted from complete embedding and partially exposed on the outer surface of the circuit mounting case. This allows the bus bar to maintain electrical connection functionality while reducing the resin thickness requirement, thereby providing space for connection formation without compromising insulating performance where the bus bar is embedded.
Solution Approach 2:
The bus bar arrangement transitions from a fully internal three-dimensional embedding to a partial surface exposure configuration. This dimensional change allows the bus bar to extend from the inner portion through the outer surface of the circuit mounting case, enabling connection formation in a different spatial dimension while maintaining embedded insulating protection.
2Strength
If the bus bar is embedded in the resin, then the structural integrity is improved, but the mounting area is increased
Solution Approach 1:
By extracting the bus bar from complete embedding and exposing it partially on the outer surface, the resin thickness required for structural support is reduced. This allows the circuit mounting case to achieve the necessary structural integrity with less material, thereby reducing the overall mounting area of the actuator control unit.
Solution Approach 2:
The design changes the geometric parameters of the bus bar arrangement, specifically the embedded depth and exposure length. By optimizing these parameters, the structural integrity is maintained with minimal resin thickness, enabling compact mounting area while preserving the strength of the connection structure.
3Volume of moving object
If the bus bar is partially exposed, then the compactness is improved, but the risk of conductive foreign matter contact is increased
Solution Approach 1:
An insulating structure is introduced as an intermediary element that covers the exposed portion of the bus bar on the outer surface of the circuit mounting case. This insulating cover acts as a mediator, allowing the bus bar to be partially exposed for connection purposes while preventing direct contact with conductive foreign matter, thus maintaining compactness without increasing electrical hazard risk.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design achieves a significant reduction in the actuator control unit's size and weight, improving its compactness and reliability while maintaining electrical connectivity and mechanical stability, suitable for applications in vehicles and industrial machinery.
Implementation Method 1
a bus bar electrically connected to the control circuit and arranged such as to be partially embedded in an inner portion of a circuit mounting case constructed by a resin and be partially exposed to an outer portion of the circuit mounting case
Data Source
AI summary
The invention achieves a further downsizing of an actuator control unit. The actuator control unit has a control circuit controlling an actuator, and a bus bar electrically connected to the control circuit and arranged such as to be partially embedded in an inner portion of a resin case and be partially exposed to an outer portion of the resin case. It is preferable to have a projection portion extending in a wiring direction of the bus bar between two bus bars wired adjacently, having a greater height than an embedded plane of the bus bar in the resin case, and made of an insulating material.