Integrated Grommet Cover Assembly for Motor Coil Guidance
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Solution Overview
Problem
The manufacturing costs of electronic power steering systems are increased due to complex assembly processes and movement issues with coils, particularly when using busbar terminals and separate grommets, which require additional fitting processes.
Innovation Solution
A cover assembly with a disc-shaped cover body featuring integrally formed grommets and protrusions that guide and secure coils, reducing the need for separate grommet assembly and simplifying the assembly process by integrating grommets with the cover body using an insert injection method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate grommets are used to protect and guide coils, then coil protection is improved, but assembly complexity increases and manufacturing costs rise
Solution Approach 1:
The grommet is integrated directly into the cover body as an integral structure, eliminating the need for separate grommet components. The cover body includes built-in grommets that guide and protect coils, merging the protective function into the existing cover structure and simplifying the assembly process.
2Reliability
If busbar terminals are used for electrical connection, then electrical connectivity is improved, but manufacturing costs increase due to pressing processes
Solution Approach 1:
The patent replaces expensive busbar terminals with a simpler, more cost-effective routing structure integrated into the cover body. The routing structure provides sufficient electrical connectivity and coil guidance without requiring complex pressing processes or expensive materials.
3Reliability
If multiple components are assembled in the housing, then functional requirements are met, but manufacturing costs increase due to multiple assembly processes
Solution Approach 1:
The grommet is merged with the cover body to form an integral component, reducing the total number of parts that need to be assembled. This integration eliminates separate grommet assembly steps and reduces overall manufacturing complexity while maintaining all necessary functions.
Solution Approach 2:
The cover body is designed to perform multiple functions: it provides structural enclosure, guides coils through integrated grommets, and protects internal components. This multi-functionality reduces the need for separate specialized components and simplifies the overall assembly process.
4Manufacturing precision
If grommets are fitted to coil end portions, then coil positioning is improved, but the number of processes increases and manufacturing costs rise
Solution Approach 1:
The grommets are pre-formed as integral parts of the cover body during cover manufacturing, rather than being added separately during coil assembly. This preliminary action ensures precise coil positioning is built into the structure itself, eliminating subsequent fitting operations.
Data Source
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AI summary
One embodiment relates to a cover assembly, a motor and an electric steering device including the same, the cover assembly comprising: a disc-shaped cover body; and a plurality of first holes formed at the cover body, wherein a grommet is disposed in the first hole, and the grommet is formed to extend and protrude from the upper surface of the cover body. Therefore, the cover assembly can stably guide the arrangement of the motor coils since the grommet is formed to be integrated with the cover body such that the first holes formed at the cover body are extended.