Integrated System Controller Drive Device Connector Placement
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Solution Overview
Problem
Existing integrated systems for hybrid vehicles face challenges in efficiently coupling control units with drive devices, leading to suboptimal electrical connections and mechanical stability, particularly in compact designs where space and vibration dampening are concerns.
Innovation Solution
The integration of a control unit and a controlled unit through a connector system where the control unit is mounted on top of the controlled unit, with connectors disposed between them to ensure electrical coupling via a fastening supporting member, allowing for a compact and stable configuration that maintains coupling under gravitational and fastening forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control unit is mounted on top of the controlled unit with connectors disposed between them, then the electrical coupling and mechanical stability are enhanced, but the device complexity increases due to the additional fastening supporting member and connector system
Solution Approach 1:
The patent introduces a fastening supporting member as an intermediary component between the control unit and controlled unit. This member includes a fastening portion that couples to the controlled unit and a support portion that supports the control unit, while connectors are disposed between these portions to establish electrical coupling. The intermediary structure resolves the contradiction by providing dedicated pathways for both mechanical support and electrical connection, enhancing reliability without overly complicating the overall assembly.
2Stability of the object's composition
If the control unit and controlled unit are coupled using a fastening supporting member, then the mechanical stability is improved, but the weight of the integrated system increases
Solution Approach 1:
The fastening supporting member is designed to perform multiple functions simultaneously: it provides mechanical fastening to the controlled unit, supports the control unit in a stable position, and serves as a pathway for electrical connectors. This multi-functionality allows the system to achieve improved mechanical stability without proportionally increasing weight, as a single component structure fulfills multiple roles rather than requiring separate elements for each function.
3Object-affected harmful factors
If the connectors are disposed within the area through which the line segment passes (perpendicular to virtual line connecting center of gravity and fastening supporting member), then the vibration is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by specifically positioning connectors within a defined area on the fastening supporting member - namely, within the area through which a line segment passes that is perpendicular to the virtual line connecting the center of gravity of the control unit and the fastening supporting member. This localized positioning strategy reduces vibration by optimizing the distribution of electrical connections relative to the gravitational and fastening forces. The principle balances vibration reduction with manufacturability by defining a clear geometric criterion for connector placement rather than requiring extreme precision.
Data Source
AI summary
An integrated system includes a controller, a drive device, and a fastening supporting member. The controller has a controller connector. The drive device has a drive device connector which is connected to the controller connector so that the drive device is electrically coupled to the controller. Via the fastening supporting member, the controller and the drive device are maintained in an electrically coupled state in which the drive device connector is connected to the controller connector. At least part of the controller connector and the drive device connector, as viewed from a vertical direction, is disposed within an area from a first line segment which is perpendicular to a virtual line connecting a center of gravity of the controller and the fastening supporting member and which passes the center of gravity to a second line segment which is perpendicular to the virtual line and which passes the fastening supporting member.