Motor Control Unit Leadframe Pins for Connector-Free Motor Assembly
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Solution Overview
Problem
The existing methods for connecting the pins of a leadframe to the terminals of an electric motor in a motor control unit are complex and require separate connectors and multiple welding points, making the assembly process cumbersome and inefficient.
Innovation Solution
The pins of the leadframe are designed with a weak portion of reduced material thickness or without reinforcement, allowing them to be bent into an assembly orientation for contact with the electric motor terminals, eliminating the need for separate connectors and reducing the number of welding points, with the option to bend vertically or horizontally by 90 degrees for easier assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connectors are used to bridge pins and terminals, then electrical connection is achieved, but device complexity increases
Solution Approach 1:
The patent merges the connector function directly into the pin structure by integrating a bending portion that directly contacts the terminal. This eliminates the need for separate connector components, reducing device complexity while maintaining reliable electrical connection between the leadframe pins and motor terminals
2Reliability
If multiple welding points are used to connect connectors, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent extracts the connector component from the system and replaces it with an integrated pin structure featuring a bending portion. This eliminates the need for multiple welding points on separate connectors, simplifying the manufacturing process to require only the welding of pins directly to terminals while maintaining connection reliability
3Device complexity
If pins are bent into assembly orientation, then connector elimination is achieved, but pin structural integrity may be compromised
Solution Approach 1:
The patent applies local quality by creating a bending portion with specific geometric characteristics (reduced cross-section or different material properties) at a localized region of the pin. This allows the pin to be bent into the assembly orientation to eliminate connectors while maintaining sufficient structural integrity in the critical connection regions, resolving the contradiction between structural simplification and strength requirements
Data Source
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AI summary
Motor control unit (7) for an electric motor (5) for actuating a valve of a vehicle, the motor control unit (7) comprising a leadframe at least partially overmolded with a plastic housing, the leadframe supporting a number of motor control devices arranged in the housing, the leadframe having at least two pins (9) providing terminals for electrical connection to an electric motor (5), wherein the pins (9) protrude from the plastic housing and have - a first portion (21) being in contact with the plastic housing; - a second portion (17) for making contact with terminals (13) of the electric motor (5) and - a weak portion (23) arranged between the first portion (21) and the second portion (17), wherein the weak portion (23) is adapted to being bent out of an original orientation into an assembly orientation in which the second portion (17) of the pin (9) makes contact with a terminal (13) of the electric motor (5) during assembly with the electric motor (5).