Electric Power Steering Control Unit Connector Assembly
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Solution Overview
Problem
Existing drive devices require redesigning of connectors and their surrounding components each time the vehicle changes, necessitating changes in connector type, shape, and orientation, which complicates the design and manufacturing processes.
Innovation Solution
A control unit with a connector assembly body that includes a large-current power connector and small-current signal connector, both aligned with the motor output shaft, and a component mounting section for components like capacitors and coils, allowing these components to be disposed in separate regions, enabling efficient design and manufacturing by allowing changes only in the connector portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connector type, shape, or orientation is changed to match different vehicle specifications, then the adaptability to different vehicles is improved, but the device complexity increases because the cover shape, connector, and surrounding components must all be redesigned
Solution Approach 1:
The control unit is divided into a motor unit and a separable connector assembly. The connector assembly can be detached and replaced independently from the motor unit, allowing different connector types to be used with the same motor unit. This segmentation enables adaptability to different vehicle specifications without redesigning the entire device.
Solution Approach 2:
The motor unit is designed with a universal interface that can accommodate multiple types of connectors. By making the connector assembly separable and interchangeable, the same motor unit can be universally applied to different vehicles with different connector requirements, reducing overall system complexity.
2Manufacturing precision
If the connector shape and cover holes are redesigned for different connector types, then the manufacturing precision is improved for specific applications, but the loss of time increases due to repeated redesign and remanufacturing processes
Solution Approach 1:
The motor unit is pre-assembled with standardized mounting interfaces and connection structures that are designed to accommodate multiple connector types. This preliminary preparation allows for quick replacement of connector assemblies without requiring redesign or remanufacturing of the motor unit, thereby reducing time loss while maintaining manufacturing precision.
3Adaptability or versatility
If the connector orientation is changed to match different vehicle installations, then the adaptability is improved, but the device complexity increases because the cylindrical part and overall structure must be redesigned
Solution Approach 1:
The connector assembly is designed to be dynamically reconfigurable through simple rotation or repositioning of the separable connector relative to the motor unit. This allows the connector orientation to be adjusted to match different vehicle installations without requiring structural redesign of the cylindrical part or overall device architecture.
Data Source
AI summary
A connector assembly body has: on an end surface on an opposite side to an output side of a motor; a large-current connector of a power supply system, with large-current connector being disposed in the same direction as the motor output shaft; a small-current connector of a signal system, with the small-current connector being disposed in the same direction as the motor output shaft; and a component mounting section including at least one of a capacitor and a coil, and the large-current connector, the small-current connector and the component mounting section are disposed separately in respective regions.