Motor Capacitor Holder Layout for Vibration-Resistant EPS Assembly
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Solution Overview
Problem
Conventional electric rotating machine apparatuses face challenges in achieving high vibration resistance and efficient assembly due to the structural limitations of integrating control units and power modules, particularly with large components like smoothing capacitors, which can lead to connection failures under impact or vibration.
Innovation Solution
The apparatus integrates a bus-bar holder and a capacitor holder to securely position and connect smoothing capacitors radially outside the electric rotating machine, using snap fittings and adhesives to enhance vibration resistance and assembly efficiency, while arranging capacitors in an axial direction to minimize space and maximize stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If smoothing capacitors are held only by the connection portion between the terminal and bus bar, then assembly is simple, but vibration resistance is poor and connection failure may occur
Solution Approach 1:
A holder is introduced as an intermediary component between the smoothing capacitors and bus bar. The holder has a first holding portion that secures the capacitors and a second holding portion that connects to the bus bar, serving as a mediator that provides both secure mounting and reliable electrical connection while resisting vibration.
Solution Approach 2:
The holding structure is segmented into distinct functional portions: a first holding portion for securing the smoothing capacitors and a second holding portion for connecting to the bus bar. This segmentation allows each portion to be optimized for its specific function while working together to solve the vibration resistance problem.
2Adaptability or versatility
If control unit expands in radial direction of the motor, then all components can be integrated, but mounting restriction in vehicle makes it difficult to mount
Solution Approach 1:
The control unit components are arranged in the axial direction (lengthwise along the output axle) rather than expanding in the radial direction. This dimensional change allows full integration of the control unit while maintaining a compact radial profile that fits vehicle mounting restrictions.
3Area of stationary object
If power module and control board are erected in parallel in output-axle direction, then radial-direction area is reduced, but assembly complexity increases
Solution Approach 1:
The holder integrates multiple functions: it holds the smoothing capacitors, provides electrical connection to the bus bar, and reduces radial space. By merging these functions into a single component, the design achieves compact radial dimensions without proportionally increasing overall system complexity.
Data Source
AI summary
An electric rotating machine apparatus includesan electric rotating machine having a windings and an output axle,a power module having a switching device connected with the winding,a bus bar that is held by a bus-bar holder and is included in a power-supply path to the power module,two or more smoothing capacitors connected with the bus bar, anda capacitor holder in which at a more outer side in the radial direction of the electric rotating machine than the bus-bar holder is, the two or more smoothing capacitors are arranged in the axial direction of the electric rotating machine, and that holds the two or more smoothing capacitors from the outer circumferential side of the electric rotating machine.