Flat Cable Resolver Connection for Compact EPS Motors
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Solution Overview
Problem
Existing electric power steering motors have a large axial dimension due to the use of flexible lead wires connecting the resolver and drive control circuit, making them bulky and complicated to connect.
Innovation Solution
A motor design incorporating a flat cable with conductor lines arranged in the width direction, coated with an elongated material, which is flexible in the thickness direction, is used to connect the resolver to the control unit, reducing the axial dimension and simplifying the connection process by aligning the cable's width direction with the motor's circumference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If flexible lead wires are used to connect the resolver and drive control circuit, then electrical connection is achieved, but the axial dimension of the motor body is enlarged
Solution Approach 1:
The patent transitions from using flexible lead wires extended in the axial direction to using a flat cable arranged in the circumferential direction. This dimensional change allows the cable to extend radially outward from the motor body, significantly reducing the axial dimension while maintaining electrical connection functionality between the resolver and drive control circuit.
Solution Approach 2:
The patent employs a flat cable with an elongated coating material that provides flexibility in the thickness direction. This thin-film structure allows the cable to be easily connected to the control unit while maintaining a compact profile, eliminating the need for complex mechanical adjustments and simplifying the connection process.
2Ease of operation
If multiple flexible lead wires are extended from the motor body, then electrical connection is established, but the connection process becomes complicated
Solution Approach 1:
The patent consolidates multiple conductor lines into a single flat cable structure with an integrated elongated coating material. This merging of multiple individual lead wires into one unified flat cable simplifies the connection process, as the entire cable can be connected to the control unit as a single unit rather than managing multiple separate wires.
Solution Approach 2:
The flat cable's flexible thin-film structure with elongated coating material enables easy connection to the control unit without requiring complex mechanical adjustments. The flexibility in the thickness direction allows the cable to be easily maneuvered and connected, significantly improving ease of operation.
Data Source
AI summary
A motor has a motor body and a control unit, which is joined to the motor body. A resolver is connected to the control unit through a flat cable. The flat cable is arranged such that the width direction of the flat cable corresponds with a circumferential direction of the motor body. The flat cable extends outwardly in a radial direction of the motor case.