Electric Power Steering Circuit Board Integration
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Solution Overview
Problem
The existing electric power steering apparatus has a large size and high manufacturing cost due to its three-layer structure, which requires additional connecting members for electrical connections, reducing reliability.
Innovation Solution
A single multilayer board integrates the power board, housing, and control board, eliminating the need for external connecting members by using a circuit board with insulating and conductor layers, and a heat sink for high conductivity, allowing electrical connection through conductor layers and through holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-layer structure with separate power board, housing, and control board is used, then electrical connections can be established, but the apparatus becomes large in size and requires additional connecting members increasing manufacturing cost and assembly complexity
Solution Approach 1:
The patent merges the power board, housing, and control board into a single integrated circuit board structure. The circuit board serves multiple functions simultaneously: it provides the structural housing, mounts the power semiconductor elements, and provides the control circuitry mounting surface. This eliminates the need for separate connecting members and reduces the number of electrical connection points, thereby reducing apparatus size and manufacturing cost while maintaining electrical connection reliability.
2Ease of manufacture
If multiple connecting members are used to electrically connect power board, housing, and control board, then electrical connections are established, but the number of connected locations increases reducing reliability and increasing assembly time
Solution Approach 1:
The circuit board integrates the functions of power board, housing, and control board into a single component, eliminating the need for multiple connecting members. This reduction in the number of connected locations directly improves electrical connection reliability by reducing potential failure points, while simultaneously reducing manufacturing cost by eliminating the need for multiple connectors and their associated assembly operations.
3Quantity of substance
If a three-layer structure with laminated boards is used, then electrical connections can be made between layers, but the height of the control unit becomes large increasing apparatus size
Solution Approach 1:
The patent consolidates three separate laminated boards (power board, housing, control board) into a single integrated circuit board. This merging of components reduces the overall height and volume of the control unit while maintaining all necessary electrical connection functions. The single circuit board structure eliminates the cumulative height of multiple laminated layers and the spacing required between them.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces the size and cost of the apparatus while improving the reliability of electrical connections, minimizing electric power loss and suppressing electromagnetic noise.
Implementation Method 1
a heat sink that receives the circuit board and is made of a metal material of high conductivity
Data Source
AI summary
An electric power steering apparatus requires no external connecting member connecting between a power main body and a control main body, and hence can be reduced in size and cost, and the reliability of electrical connection between the power main body and the control main body can be improved. High current parts constituting the power main body and low current parts constituting the control main body are mounted on opposite sides of a circuit board, and are electrically connected with one another via conductor layers of the circuit board and through holes formed therein.