Cable Assembly Ground Terminal Bending for Motor Noise Reduction
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Solution Overview
Problem
Motors and inverters generate electromagnetic wave noise during high-speed rotation and switching operations, leading to degraded device performance and compliance issues with regulatory criteria, particularly in the automobile industry.
Innovation Solution
A cable assembly with a conductive core, electromagnetic wave shielding layer, and a connector featuring a ground terminal portion with bent terminals that connect to both the shielding layer and the motor cover, effectively grounding electromagnetic waves and reducing noise interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If electromagnetic wave shielding is implemented in the cable assembly, then electromagnetic wave noise is reduced, but device complexity increases
Solution Approach 1:
The electromagnetic wave shielding layer is nested within the cable assembly structure, with the cable core positioned centrally and the shielding layer wrapped around it. This nested configuration allows the shielding function to be integrated into the existing cable structure without requiring separate external shielding components, thereby reducing overall device complexity while maintaining effective electromagnetic noise reduction.
Solution Approach 2:
The electromagnetic wave shielding layer acts as an intermediary element between the cable core and the external environment. It mediates the interaction between electromagnetic waves and the cable assembly by absorbing or reflecting noise while allowing power transmission to continue uninterrupted, thus reducing harmful electromagnetic effects without fundamentally altering the cable's primary function.
2Reliability
If a ground terminal portion with bent terminals is added to the connector, then grounding effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The ground terminal portion incorporates bent terminals that can flex and adapt during assembly. The bending allows the terminal to conform to slight variations in alignment between connector components, providing a dynamic adjustment capability that ensures reliable grounding contact while simplifying the assembly process compared to rigid, precision-machined grounding structures.
Solution Approach 2:
The bent terminal configuration uses curved geometries instead of straight, rigid connections. This curvature provides mechanical flexibility and stress distribution advantages, allowing the grounding path to accommodate manufacturing tolerances and assembly variations while maintaining effective electrical contact, thereby improving reliability without requiring ultra-precise manufacturing.
3Object-affected harmful factors
If the ground terminal portion connects to both the shielding layer and motor cover, then electromagnetic noise removal is enhanced, but device complexity increases
Solution Approach 1:
The ground terminal portion merges multiple grounding functions into a single integrated component. It simultaneously connects the electromagnetic wave shielding layer and the motor cover through its bent terminal structure, creating a unified grounding path that eliminates electromagnetic noise at multiple points in the system without requiring separate grounding components or complex wiring arrangements.
Solution Approach 2:
The ground terminal portion serves multiple functions: it provides the primary grounding path for the cable assembly, connects the shielding layer to ground potential, and establishes an additional grounding connection to the motor cover. This multi-functional design enhances electromagnetic noise removal capability while avoiding the need for separate dedicated components for each grounding function.
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 cable assembly and motor configuration effectively remove electromagnetic wave noise by grounding it, improving device performance and compliance with electromagnetic interference regulations.
Implementation Method 1
an electromagnetic wave shielding layer, and a cable covering the electromagnetic wave shielding layer
Implementation Method 2
a ground terminal portion disposed at the connector and having a first terminal electrically connected to the electromagnetic wave shielding layer and a second terminal disposed to be exposed at the connector, wherein the first terminal and the second terminal are connected by bending
Data Source
AI summary
A cable assembly includes a cable having a conductive core, an electromagnetic wave shielding layer, and an internal insulation layer between the conductive core and the electromagnetic wave shielding layer, a connector connected to one end of the cable, and a ground terminal portion disposed at the connector and having a first terminal electrically connected to the electromagnetic wave shielding layer and a second terminal disposed to expose from the connector, wherein the first terminal and the second terminal are connected by bending. The cable assembly provides an advantageous effect of implementing a grounding arrangement at the cable assembly coupled to the motor in a vertical direction that is parallel with the shaft direction of the motor by forming the first terminal and second terminal of the ground terminal portion by bending.