Electric Machine Control Unit Through-Passage Connector Protection
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Solution Overview
Problem
The existing control units for electric superchargers in motor vehicles face challenges in connecting electrical components without damaging the electronics due to limited space and the risk of soldering projections, which can harm the control unit during assembly and operation.
Innovation Solution
A control unit design featuring a box with a base and primary cover that includes a through passage for connectors, providing protection against soldering splashes and allowing precise arrangement of connectors, along with optional sealing elements and a secondary cover for enhanced protection and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the control unit uses a compact design with base and cover close together, then the space occupied is reduced, but the risk of solder spatter damaging electronics increases
Solution Approach 1:
The control unit housing is segmented into a base and a cover that can be separated. The base contains the electronics while the cover provides protection during soldering. This segmentation allows the soldering process to be performed on connectors extending through the base without exposing sensitive electronics in the cover to solder spatter, while still maintaining a compact overall design when assembled.
Solution Approach 2:
Connectors are positioned as intermediary elements that extend through the base from the electronics side to the external connection side. This allows soldering to be performed on the external side of the base without the solder material reaching the electronics housed in the cover, effectively using the connector and base structure as a protective intermediary barrier.
2Volume of moving object
If the control unit housing is made compact with base and cover close together, then space is saved, but connection reliability during soldering becomes difficult to ensure
Solution Approach 1:
The housing is divided into base and cover segments that can be positioned at optimal distances for reliable soldering operations. The base can be designed with sufficient height to accommodate connectors and provide stable mounting, while the cover protects the electronics. This segmented approach allows each component to be optimized for its function without compromising overall compactness.
3Adaptability or versatility
If separate power board and control board are used, then functional differentiation is improved, but the number of components and space requirements increase
Solution Approach 1:
The power board and control board are merged into a single integrated control unit housing. The base contains the power electronics while the cover houses the control electronics, maintaining functional differentiation through spatial separation within the same housing rather than requiring separate physical units. This reduces component count and simplifies assembly while preserving the benefits of separate functional areas.
Data Source
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AI summary
The invention relates to a control unit (10) for controlling an electric machine (50), in particular for a motor vehicle, the control unit comprising: a housing (12) comprising a base (16) receiving at least one power electronics unit (18), the power electronics unit comprising at least one connector (20) intended to be electrically connected to a corresponding connector (52) of the electrical machine, a primary cover (14) closing the housing. The invention is characterized in that the control unit comprises at least one through-passage (30) which extends between the base and the primary cover through which said connector of the power electronics unit passes and is intended to receive the corresponding connector of the electric machine.