Angled Motor Terminals for Compact Drive Device Volume Reduction
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Solution Overview
Problem
Conventional driver devices for rotating electric machines have a large volume due to the need for jigs during welding, which increases the size of welded parts and limits the compactness of the device.
Innovation Solution
A driver device design that includes a motor section with a stator and rotor, a semiconductor module with angled motor terminals, and a heat sink, where the motor terminals are angled relative to the motor wire and connected with solder, eliminating the need for jigs and reducing the device's overall volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding with jigs is used to connect motor terminals to motor wires, then reliable electrical connections are achieved, but the device volume increases due to larger welded parts required for jig attachment
Solution Approach 1:
The invention extracts and eliminates the jig from the welding process by designing motor terminals with self-positioning structures (protrusions fitting into recesses, angled configurations) that enable direct connection to motor wires without external holding fixtures, thereby reducing device volume while maintaining connection reliability
Solution Approach 2:
The motor terminal structure performs self-positioning and self-holding functions through its geometric design (angles, protrusions, recesses), eliminating the need for external jigs to hold the welded parts during the connection process
2Duration of action of moving object
If motor terminals are designed with angles greater than 0 degrees relative to motor wires, then connection life is extended through better mechanical strength, but manufacturing complexity increases
Solution Approach 1:
The invention optimizes the motor terminal angle parameter within a specific range (greater than 0 degrees but not exceeding 90 degrees) to achieve the best balance between connection life and manufacturing ease, avoiding excessive angles that would complicate manufacturing while ensuring sufficient mechanical strength
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 angled motor terminals allow for a longer connection life and reduce the device's volume by eliminating the need for jigs, while maintaining efficient electrical connections.
Implementation Method 1
The heat sink has a module mounting surface that extends in an axially outward direction from the axial end of the motor section. The semiconductor module is disposed on the module mounting surface.
Implementation Method 2
The heat sink is disposed on the axial end of the motor section from out of which the motor wire extends
Implementation Method 3
The extension region of the motor terminal is angled relative to a perpendicular line that is perpendicular to the motor wire to form a terminal angle that is equal to or greater than zero degrees
Data Source
AI summary
A driver device has a semiconductor module in which a motor terminal extends from a molded body and is connected to a motor wire. A heat sink of the driver device has a module mounting surface, which extends axially outward from an axial end of the motor section, on which the semiconductor module is fastened. The motor terminal includes a base region on a molded body side of a bend location and an extension region on a tip side of the bend location. The extension region has a connection portion on which an insertion hole receives the motor wire. A terminal angle between the extension region and a perpendicular line perpendicular to the motor wire is greater than zero degree. As such, the volume of the driver device is reduced.