Electric Power Steering Connector Stress Management
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Solution Overview
Problem
Existing electric power steering apparatuses face challenges in reducing size and weight while maintaining mountability and preventing electrical connection failures due to stress from connector insertion and removal, particularly in integrated motor and control unit configurations.
Innovation Solution
The electric power steering apparatus integrates a motor and control unit in the axial direction of the motor's rotating shaft, featuring a motor case, a frame, and a housing that bears stress from connector insertion and removal, with connectors formed integrally on an intermediate member and protruding through a notch in the housing, thereby reducing stress on the circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connectors are mounted directly to the circuit board or power modules, then workability is improved, but electrical connection failure occurs more likely due to stress from insertion and removal
Solution Approach 1:
The patent introduces a connector holder as an intermediary component between the circuit board and the connector. The connector holder absorbs the stress generated during connector insertion and removal, preventing this stress from being transmitted to the circuit board or power modules. This mediator structure maintains both ease of manufacture (direct connector mounting) and electrical connection reliability (stress isolation).
2Reliability
If a large number of members and connecting terminals are disposed inside the case, then electrical and mechanical connections are achieved, but device complexity and assembly steps increase
Solution Approach 1:
The patent combines the connector holder with existing structural components of the motor assembly. The connector holder is integrated into the housing structure, merging multiple functions (structural support, connector mounting, stress absorption) into a single integrated component. This reduces the total number of discrete members and simplifies the assembly process while maintaining reliable electrical and mechanical connections.
3Volume of moving object
If motor and control unit are integrated in axial direction, then size and weight are reduced, but stress management during connector operation becomes more critical
Solution Approach 1:
The connector holder serves as a stress-absorbing intermediary that is particularly important in the integrated axial configuration where space is constrained. By positioning the connector holder between the connector and the circuit board, it provides a dedicated stress management zone that protects the integrated assembly from connection stresses without requiring additional radial or axial space.
Data Source
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AI summary
The present invention provides an electric power steering apparatus that enables reductions in size, reductions in weight, and improvements in mountability, and also enables the occurrence of electrical connection failure in the circuit board that results from inserting and removing connectors to be suppressed. In the electric power steering apparatus according to the present invention, a circuit board and an intermediate member are disposed so as to be juxtaposed in an axial direction of a rotating shaft, a connector is formed integrally on the intermediate member, and is disposed so as to pass through and protrude from a notch in a housing, and at least one of a cylindrical portion of a motor case, a frame, and the housing is configured so as to bear stress in the axial direction of the rotating shaft that acts on the connector during insertion and removal of the connector.