Electric Power Steering ECU Layout for Heat Dissipation and Assembly
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Solution Overview
Problem
Existing electronic control units for electric power steering systems face challenges in achieving a compact, low-cost, and easy-to-assemble design while ensuring reliable operation and effective heat dissipation.
Innovation Solution
The electronic control unit is designed with a first and second power board, each with a different length connector, allowing for improved assembly characteristics and heat dissipation through a heat sink sandwiched between the power boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single power board is used in the electronic control unit, then the structure is simple and cost is low, but heat dissipation is insufficient and reliability is reduced
Solution Approach 1:
The power board is divided into two separate power boards (first power board and second power board) instead of using a single power board. Each power board is independently connected to the connector plate through its own connector, allowing for better heat dissipation and improved reliability while maintaining assembly simplicity through modular design.
Solution Approach 2:
The two power boards are arranged in a nested configuration within the electronic control unit housing, with each power board positioned at different distances from the connector plate. This nested arrangement allows both power boards to coexist in a compact space while maintaining independent thermal zones for effective heat dissipation.
2Ease of manufacture
If power boards are arranged at different distances from the connector plate, then heat dissipation is improved and assembly is easier, but connector length variation increases manufacturing complexity
Solution Approach 1:
Different connector lengths are used to match the specific spatial requirements of each power board's position. The first connector is designed with a first length suitable for connecting the first power board, while the second connector has a second length appropriate for the second power board. This localized adaptation of connector dimensions simplifies assembly by accommodating natural positioning variations without requiring complex adjustment mechanisms.
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 configuration results in a compact, cost-effective, and easy-to-assemble electronic control unit with enhanced reliability and heat dissipation capabilities, ensuring safe and reliable operation of the electric power steering system.
Implementation Method 1
a heat sink may be provided inside of the electronic control unit and arranged in thermal contact with a housing of the electric power steering system or electric motor
Data Source
AI summary
An electronic control unit is provided for an electric power steering system. The electric power steering system includes a housing and an electric motor. The electronic control unit is arranged inside the housing and is electrically connected to the electric motor. The electronic control unit includes a first power board having a first electric motor connector for electric connection with the electric motor, and a second power board having a second electric motor connector for electric connection with the electric motor. A connector plate of the electronic control unit is electrically connected by at least one plug connector to the first power board via at least one first power connector, and to the second power board via at least one second power connector. The at least one first power connector is shorter than the at least one second power connector. An electric power steering system is also provided.