Motor Driver Circuit Board Terminal Arrangement for Welding Reliability
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Solution Overview
Problem
Existing motor driver designs for valve timing adjusting apparatuses face challenges in ensuring reliable electrical connections between stacked circuit boards due to manufacturing tolerances, leading to potential gaps and deformation of terminals, which can result in welding issues and joint failure over time.
Innovation Solution
The motor driver design involves arranging first and second circuit boards perpendicular to each other's planes, with terminals spaced and connected in a specific sequence to minimize gaps and deformation during welding, ensuring strong and durable connections by welding along a perpendicular direction, thereby reducing the likelihood of terminal ripping-off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If circuit boards are stacked one after another to increase installation area, then installability is improved, but manufacturing precision of terminal alignment deteriorates due to cumulative tolerances
Solution Approach 1:
The patent divides the terminal connection process into two separate operations: first connecting terminals at one end of the circuit boards, and then connecting terminals at the other end. This segmentation allows each connection operation to be performed independently with proper alignment, preventing cumulative tolerance errors that would occur if all terminals were connected in a single operation.
Solution Approach 2:
The patent performs preliminary alignment and connection of terminals at one end of the circuit boards before proceeding to connect terminals at the other end. This preliminary action establishes a reference alignment that ensures subsequent connections maintain proper positioning, thereby preserving manufacturing precision across the entire assembly.
2Reliability
If terminals are deformed by applying load to close gaps, then electrical connection is achieved, but reliability deteriorates due to terminal ripping-off after long term use
Solution Approach 1:
The patent segments the terminal connection process into two independent operations at opposite ends of the circuit boards. By connecting terminals at one end first, then connecting terminals at the other end separately, the patent eliminates the need to apply excessive loads that would cause terminal deformation, thereby maintaining both positioning accuracy and joint durability.
Solution Approach 2:
The patent performs preliminary connection of terminals at one end before addressing the other end. This preliminary action allows for proper alignment and reduces gaps without requiring terminal deformation, ensuring that terminals maintain their structural integrity and resist ripping-off during long-term use.
3Ease of manufacture
If terminals are arranged in opposite sequences at different ends of circuit boards, then ease of manufacture is improved, but reliability worsens due to gap formation and welding issues
Solution Approach 1:
The patent segments the manufacturing process into distinct steps: first arranging and connecting terminals at one end with a specific sequence, then arranging and connecting terminals at the other end with the same sequence. This segmented approach maintains ease of manufacture while ensuring reliable welded joints by eliminating gap formation that would result from using opposite sequences.
Solution Approach 2:
The patent applies the same terminal arrangement sequence at both ends of the circuit boards rather than using opposite sequences. This homogeneity ensures consistent alignment and proper spacing between terminals, maintaining both ease of manufacture and welded joint strength by preventing gap formation during assembly.
Data Source
AI summary
In a motor driver of a valve timing adjusting apparatus, each terminal at a first end side of a first circuit board is arranged after a corresponding terminal at a first end side of a second circuit board in a predetermined direction, which is generally perpendicular to a plane of each circuit board. Furthermore, each terminal at a second end side of the first circuit board is arranged after a corresponding terminal at a second end side of the second circuit board in the predetermined direction.