EPS Power Pack Connector Plate With Metal Ring Press Fit
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Solution Overview
Problem
The existing electric power steering (EPS) systems face complexity in assembly and shipping due to the use of metal connector plates, which require multiple nuts and studs for coupling, increasing manufacturing and assembly processes while providing advantages in grounding, conductivity, and heat transfer.
Innovation Solution
A manual power pack assembly for EPS systems using a plastic connector plate with a metal ring for press fit coupling, reducing the need for metal fasteners and simplifying the assembly process, and incorporating metal pins for grounding and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal connector plate is used, then grounding, conductivity, and heat transfer are improved, but device complexity and assembly difficulty increase due to multiple nuts and studs
Solution Approach 1:
The connector plate uses a composite structure combining plastic and metal components. The plastic body provides structural support and insulation, while integrated metal features (such as metal inserts or coated surfaces) provide grounding and conductivity pathways. This composite approach maintains electrical reliability while eliminating the need for separate metal fasteners and reducing assembly complexity.
Solution Approach 2:
The invention merges multiple functions into the connector plate itself. The plate integrates structural support, electrical grounding, thermal conduction, and mechanical fastening capabilities into a single component. By combining these functions, the design eliminates the need for separate studs and nuts, reducing the number of parts and simplifying assembly while maintaining grounding and heat transfer through the integrated metal features.
2Strength
If a metal connector plate with multiple fasteners is used, then structural strength is improved, but ease of manufacture and shipping are worsened due to increased part count
Solution Approach 1:
The connector plate combines multiple components into a single integrated part. The structural strength previously provided by metal studs and nuts is now incorporated into the plate itself through integrated metal fastening features or reinforced结构设计. This reduction in part count simplifies manufacturing processes, reduces assembly steps, and decreases shipping volume and complexity.
Solution Approach 2:
The use of composite materials (plastic with metal reinforcements or inserts) allows the connector plate to achieve structural strength comparable to all-metal designs. The metal inserts or coated regions provide the necessary mechanical strength for fastening, while the plastic matrix provides structural support and insulation. This composite approach maintains strength requirements while simplifying the overall assembly and reducing part count.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the number of metal mechanical fasteners required, simplifying manufacturing, shipping, and assembly while maintaining essential functions like grounding and heat transfer, thereby enhancing the efficiency and ease of handling in EPS systems.
Implementation Method 1
a metal ring disposed on an inner diameter of the cylinder and in contact with the outer diameter of the motor housing
Implementation Method 2
The metal provides certain advantages and assists with grounding, conductivity, and heat transfer
Data Source
AI summary
A manual power pack assembly for an electric power steering (EPS) system includes a motor housing at least partially enclosing a motor and having an outer diameter. The manual power pack assembly also includes a connector plate formed of a material comprising plastic, the connector plate having a first side, a second side, and a cylinder extending from the first side. The manual power pack further includes a metal ring disposed on an inner diameter of the cylinder and in contact with the outer diameter of the motor housing.


