Electric Power Steering Substrate Laser Welding
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Solution Overview
Problem
Existing electric power steering apparatuses face issues with size, cost, and reliability due to the need for a large metal substrate area for component attachment and the complexity of connections between the metal substrate and connector terminals, leading to positional shifts and low reliability of soldered connections.
Innovation Solution
The apparatus incorporates a metal substrate with laminated insulating and conductor layers, connector terminals made of conductive material, and metal elements welded to both the substrate and terminals, reducing the number of components and using laser welding for connections to enhance reliability and reduce size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the connecting member is fixedly attached onto the metal substrate to prevent floating during soldering, then the connecting member remains stable, but the metal substrate requires a sufficient area for arrangement and tightening operation of screws
Solution Approach 1:
The patent combines the connecting member and metal substrate into an integrated structure where the connecting member is formed as an integral part of the metal substrate. This merging eliminates the need for separate attachment operations and reduces the required substrate area while maintaining stability during soldering processes.
Solution Approach 2:
The metal substrate serves multiple functions: it provides mechanical support, electrical connection, and structural integrity simultaneously. The connecting member is designed to perform both mechanical attachment and electrical connection functions, reducing the need for additional components and substrate area.
2Strength
If the connecting member is fixed onto the metal substrate, then the connecting member is securely attached, but impact force is transmitted to the component parts of the bridge circuit causing positional shifts
Solution Approach 1:
The connecting member is segmented into multiple connection points distributed across the metal substrate. This segmentation distributes the impact force across multiple locations rather than concentrating it at a single point, preventing positional shifts of sensitive component parts while maintaining secure attachment.
Solution Approach 2:
The design incorporates cushioning elements or flexible connection structures that absorb impact forces before they reach the component parts. This beforehand cushioning prevents transmission of shock loads that would cause positional shifts during the attachment process.
3Reliability
If the lead segment is connected with the circuit wiring via the leading terminal, then electrical connection is established, but the apparatus becomes large in size and high in cost
Solution Approach 1:
The patent merges the lead segment, leading terminal, and circuit wiring into an integrated structure where the metal substrate itself serves as the circuit board. This eliminates the need for separate lead segments and terminals, reducing the number of component parts while maintaining reliable electrical connections through the substrate's conductive traces.
Solution Approach 2:
The metal substrate performs multiple functions simultaneously: it serves as the circuit board, provides electrical connections through integrated traces, and offers mechanical support. This multi-functionality eliminates the need for separate lead segments and terminals, reducing device complexity and cost while maintaining connection reliability.
4Reliability
If multiple component parts are used to connect the metal substrate and connector terminals, then electrical connection is established, but the apparatus increases in size and cost
Solution Approach 1:
The patent combines multiple component parts into an integrated metal substrate structure. The substrate itself provides the electrical connection paths, eliminating the need for separate connectors, terminals, and lead segments. This merging reduces the quantity of component parts while maintaining reliable electrical connections through the substrate's conductive traces.
Solution Approach 2:
The metal substrate is designed as a multi-functional component that simultaneously provides mechanical support, electrical connection, and structural integrity. This universality eliminates the need for multiple specialized component parts, reducing both the number of parts and the overall apparatus size while maintaining connection reliability.
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 configuration reduces the size and cost of the apparatus while improving the reliability of electrical connections between the control unit and electric motor, minimizing electric power loss and suppressing electromagnetic noise.
Implementation Method 1
metal elements that have one end portions welded to the conductor layers of the metal substrate on which the power main body is mounted, and the other end portions welded to the connector terminals
Data Source
AI summary
In an electric power steering apparatus, a metal substrate and connector terminals arranged in a peripheral portion of the metal substrate are electrically connected to each other by metal elements, and conductor layers of the metal substrate and the metal elements are bonded to each other by laser welding, whereby the number of parts and a space for connection can be reduced.