Electric Pump Connector Box Relocation for Wiring Space
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Solution Overview
Problem
Existing electric pumps for brake boosters face challenges in accommodating various electrical configurations due to limited space, particularly when trying to achieve commonality of motor units and efficient wiring connections.
Innovation Solution
The design includes a motor unit with an integral power supply bus bar and a cover with a connector box, allowing for sufficient space and flexible electrical connections through a penetration hole and recessed portion, enabling easy insertion and connection of wiring, and accommodating a controller board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an intermediate connector is removably attached to a base plate as in Patent Literature 2, then the connector can be easily installed and removed, but the space for electrical configuration is limited
Solution Approach 1:
The patent relocates the connector from the base plate (bottom side) to the cover (top side) of the pump unit. This spatial relocation to another dimension allows the electrical configuration space to be positioned above the rotor assembly, avoiding interference with the rotation shaft insertion space at the center. The connector box is formed on the cover, providing adequate space for electrical components while maintaining easy accessibility for installation and removal.
2Area of stationary object
If a connector is provided at the cover as in Patent Literature 1, then sufficient space for electrical configuration is available, but the wire harness connection becomes troublesome
Solution Approach 1:
The patent introduces a power supply bus bar as an intermediary component that extends from the motor unit through a penetration hole in the pump plate to the connector box on the cover. This bus bar serves as a fixed conductor that bridges the electrical connection between the motor and the external wire harness. The wire harness connects to the bus bar at the connector box, eliminating the need to pull wires through the pump housing and simplifying the connection process while maintaining adequate electrical configuration space.
3Ease of manufacture
If the same motor is used to achieve commonality, then manufacturing cost is reduced, but different electrical configurations are required for different pump types
Solution Approach 1:
The patent divides the electrical configuration into modular components: the motor unit remains standardized for commonality, while the electrical configuration elements (connector box, power supply bus bar, controller board) are segmented and positioned on the cover. This segmentation allows the electrical portion to be customized for different pump types (with or without controller boards, different connector types) while maintaining the same motor unit, thus achieving both manufacturing efficiency and configuration flexibility.
Data Source
Figure 1
Figure 2
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AI summary
An electric pump, including: a motor unit including an end cap attached to a motor cover, and a power supply bus bar integral with the end cap; a pump unit including a rotor having a vane groove for receiving a vane and connecting to the rotation shaft and a pump plate; and a cover covering the pump unit from a side opposite to the motor unit and provided with a connector box surrounding an insertion recessed portion into which the power supply bus bar is inserted. In the electric pump, the pump plate has a penetration hole through which the power supply bus bar can be inserted, wiring is inserted into the power supply bus bar inserted through the penetration hole, the wiring protrudes from a front end side of the penetration hole, and the wiring is electrically connected to a connection unit provided in the insertion recessed portion.