Actuator Drive Unit One-Piece Connecting Element
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Solution Overview
Problem
Existing drive units for actuators, such as those in motor vehicles, face issues with unreliable electrical connections between the motor module and control module due to non-positive pin and pin receptacle connections, leading to loose contact points over time and design limitations.
Innovation Solution
A drive unit design featuring a one-piece connecting element that forms an electrically conductive connection between the motor module and control module pins, using a combination of elastically deformable contact elements and material connections to ensure reliable contact and prevent axial displacement, while allowing for more design freedom by arranging components next to each other in a radial direction within a common housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pin and pin receptacle force-fit connection is used to establish electrical connection between motor module and control module, then the connection is simple to manufacture, but the contact points become loose over time leading to unreliable electrical connection
Solution Approach 1:
The connecting element incorporates an elastically deformable contact element that dynamically adapts to maintain optimal contact pressure. The elastic deformation allows the connection to self-adjust and compensate for wear or dimensional variations, ensuring sustained reliable electrical contact throughout the actuator's operating life
Solution Approach 2:
The connecting element is pre-configured with an elastic contact element that is preliminarily deformed during assembly to create a force-fit connection. This preliminary elastic deformation establishes optimal contact pressure before operation begins, ensuring immediate and sustained reliable electrical connection without requiring adjustment during operation
2Adaptability or versatility
If pin and pin receptacle are arranged along axial direction, then the assembly is simple, but the design freedom is limited
Solution Approach 1:
The connecting element transitions the connection from a traditional axial pin-receptacle arrangement to a radial configuration. The connecting element extends radially from the motor module housing to connect with the control module, utilizing the radial dimension to achieve greater design freedom while maintaining connection simplicity
Solution Approach 2:
The connecting element serves multiple functions simultaneously: it provides mechanical connection between modules, establishes electrical connection through integrated contact elements, and enables flexible spatial arrangement. This multi-functionality increases design freedom without proportionally increasing structural complexity
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
The solution provides a reliable and secure electrical connection that maintains contact over the lifespan of the actuator, preventing displacement and ensuring consistent power transmission, while offering increased design flexibility by using a common housing for the motor and control modules.
Implementation Method 1
at least one of the pins is electrically and force-fit connected to the first connecting element via an elastically deformable contact element, the force-fit connection being resistant to displacement along the axial direction
Implementation Method 2
at least one of the pins is electrically connected to the first connecting element via a material-bonded connection
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
Drive unit (1) for an actuator (2), comprising at least a motor module (3) and a control module (4), wherein the motor module (3) has at least one electric drive (5) and the control module (4) has at least one power component (6) for controlling the drive (5); wherein the motor module (3) and the control module (4) are connected to each other via at least one electrically conductive first connection (7); wherein the first connection (7) is formed by a first motor module pin (8) and a first control module pin (9) and a one-piece first connecting element (10) electrically connecting the first motor module pin (8) to the first control module pin (9); wherein the first motor module pin (8) extends from a connection on the motor module (3) along a first axial direction (11) to a first motor module pin end (12);wherein the first control module pin (9) extends from a connection on the control module (4) along the first axial direction (11) to a first control module pin end (13).