EPS Redundant Power Connector Layout to Prevent Misassembly
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Solution Overview
Problem
In electric power steering devices with redundant systems, ensuring correct assembly and preventing instantaneous malfunctions of power source connectors is challenging due to identical external shapes, which can lead to simultaneous failures under external influences.
Innovation Solution
The implementation of power source connectors with different axial lengths and common connectors at the ends of corresponding harnesses, ensuring correct engagement and reducing mechanical interference, thereby minimizing the likelihood of erroneous assembly and instantaneous malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If power source connectors have identical external shapes to simplify manufacturing and assembly, then manufacturing cost and assembly complexity are reduced, but the risk of erroneous assembly and simultaneous malfunctions under external influences increases
Solution Approach 1:
The patent applies asymmetry by making the axial lengths of the first and second control section side power source connectors different, while keeping their external shapes substantially the same. This creates an asymmetric dimension (axial length) that prevents erroneous assembly between connectors, resolving the contradiction between manufacturing simplicity and assembly correctness.
2Device complexity
If harness lengths are standardized to reduce inventory complexity, then inventory management is simplified, but the ability to accommodate different connector configurations is reduced
Solution Approach 1:
The patent applies local quality by making the harness lengths specific and determined according to the axial heights of the respective connectors. This means each harness is locally adapted to its specific connector configuration, ensuring proper engagement and electrical connection while maintaining overall system organization.
3Quantity of substance
If all connectors are made with the same specifications to reduce part variety, then part variety and inventory requirements are reduced, but the ability to differentiate and prevent incorrect connections is lost
Solution Approach 1:
The patent uses asymmetry in the axial length dimension to differentiate between connectors. The first control section side power source connector and the second control section side power source connector have different axial heights, providing a simple visual and physical distinction that prevents incorrect assembly while maintaining similar overall connector designs.
Data Source
AI summary
An electric drive device includes: an electronic control section including a first electronic control section and a second electronic control section which constitute a redundant system, the first electronic control section and the second electronic control section being provided with a first control section side connecter and a second control section side connecter which have an identical configuration, and the first non-control section side connecter being engaged with the first control section side connecter, and the second non-control section side connecter being engaged with the second control section side connecter to correspond to the lengths of the first harness and the second harness.