Power Steering ECU Coil-Terminal Assembly Without PCB Housing
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Solution Overview
Problem
Existing electronic control units (ECUs) for electric power steering systems are limited by large dimensions, high material costs, and complex manufacturing processes due to the use of printed circuit boards (PCBs) and separate component housings, which hinder integration into vehicles and increase weight and production costs.
Innovation Solution
An ECU design featuring direct material joints between battery terminals and winding wires of an electromagnetic coil, covered by a common protective layer, eliminating the need for PCBs and separate component housings, and utilizing a process like overmolding to integrate multiple components into a single protective housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a printed circuit board (PCB) is used to mount components and establish electrical connections, then electrical connectivity and component mounting are achieved, but the overall dimensions, weight, and complexity of the electronic control unit increase
Solution Approach 1:
The patent extracts and eliminates the printed circuit board (PCB) from the electronic control unit assembly. Instead of mounting components on a PCB, the invention directly integrates the coil and battery terminals without requiring a separate PCB substrate, thereby reducing structural complexity while maintaining electrical connectivity through direct material joints.
Solution Approach 2:
The patent merges the functions of the PCB, component housings, and protective structures into a single integrated design. The coil and battery terminals are directly connected through material joints, and a common protective layer replaces separate component housings, combining multiple structural and protective functions into one unified structure.
2Object-affected harmful factors
If multiple separate component housings are used to shield components from external influences, then protection against humidity and force application is achieved, but the number of manufacturing steps and production costs increase
Solution Approach 1:
The patent combines multiple separate component housings into a single common protective layer that shields both the coil and battery terminals. This unified protective structure is applied as one integrated component rather than multiple separate housings, reducing the number of manufacturing steps and assembly operations while maintaining comprehensive protection against humidity and mechanical forces.
3Object-affected harmful factors
If individual housings are glued to components in separate manufacturing steps, then component protection is achieved, but the manufacturing process becomes time-consuming and cost-intensive
Solution Approach 1:
The patent merges the protection of multiple components under a single common protective layer that is applied in one manufacturing step. Instead of separately gluing individual housings to each component in sequential steps, the invention applies one unified protective structure that simultaneously protects the coil, battery terminals, and other components, thereby significantly reducing manufacturing cycle time and increasing productivity.
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 achieves a compact, lightweight, and cost-effective ECU with simplified manufacturing, ensuring reliable electrical connections and protection against external influences, while reducing the number of manufacturing steps and material costs.
Implementation Method 1
an electromagnetic coil (4), wherein the coil comprises a core (4.1) and at least a first winding wire (4.2) and a second winding wire (4.3), wherein the winding wires (4.2, 4.3) are at least partially wound around the core (4.1)
Implementation Method 2
the first battery terminal (2) is materially joined to the first winding wire (4.2) and the second battery terminal (3) is materially joined to the second winding wire (4.3)
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Electronic control unit (1) for use in an electric power steering system of a vehicle (50) comprising at least a first battery terminal (2), a second battery terminal (3) and an electromagnetic coil (4), wherein the coil (4) comprises a core (4.1) and at least a first winding wire (4.2) and a second winding wire (4.3), wherein the winding wires (4.2, 4.3) are at least partially wound around the core (4.1) and wherein the first battery terminal (2) is materially joined to the first winding wire (4.2) and the second battery terminal (3) is materially joined to the second winding wire (4.3) and wherein at least the battery terminals (2, 3) and the coil (4) are at least partially covered with at least one common layer of a protective material (5).