Terminal Connector Plastic Deformation for Reliable Electrical Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for electrically connecting motors and control units in electric power steering apparatuses require precise control of terminal alignment and contact pressure to maintain a stable electrical connection, which is challenging to achieve with simple terminal shapes.
Innovation Solution
A terminal connector and connection method that applies plastic deformation through machine work to form a junction site between motor-side and unit-side terminals, allowing for flexible machining processes such as hole formation, recess machining, bending, or clinch calking, which reduces the need for precise alignment and maintains contact area and pressure over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If simple terminal shapes are used for mechanical abutting and electrical connection, then device complexity is reduced, but manufacturing precision becomes difficult to control
Solution Approach 1:
The terminal connection structure is divided into multiple functional segments: the motor-side terminal with fork portions, the unit-side terminal with corresponding slots, and the junction site formation zone. This segmentation allows each part to have a simple overall shape while incorporating localized features that ensure precise alignment and contact during the plastic deformation process
Solution Approach 2:
The invention introduces an intermediary plastic deformation process as a mediator between the simple mechanical abutting of terminals and the final electrical connection. This deformation process acts as a buffer that accommodates alignment variations while ensuring reliable contact, allowing simple terminal shapes to achieve precise electrical connection through controlled deformation
2Reliability
If precise terminal alignment is controlled to maintain contact area and pressure, then electrical connection reliability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The terminal connection structure incorporates dynamic adaptability through the plastic deformation process. The terminals are designed to undergo controlled deformation during connection, allowing the contact area and pressure to self-adjust to optimal values regardless of initial alignment variations. This dynamic adjustment mechanism maintains electrical connection reliability without requiring precise pre-alignment control
Solution Approach 2:
The invention changes the physical state and geometric parameters of the terminals through controlled plastic deformation. During the deformation process, parameters such as contact area, contact pressure, and terminal shape evolve dynamically to reach optimal values for electrical connection. This parameter transformation allows reliable connection even when initial terminal dimensions and alignment are not precisely controlled
3Duration of action of stationary object
If plastic deformation with machine work is applied to form junction sites, then contact area and pressure are maintained long-term, but manufacturing process complexity increases
Solution Approach 1:
The invention merges multiple functions into the plastic deformation process: connection formation, contact area optimization, contact pressure adjustment, and long-term stability enhancement are all achieved through this single process. By combining these functions, the patent reduces the need for separate manufacturing steps while ensuring durable electrical connection
Solution Approach 2:
The plastic deformation process is designed to be self-regulating, where the material properties and geometric constraints of the terminals guide the deformation to automatically achieve optimal contact conditions. The structure itself serves to control the deformation process, reducing the need for complex external control mechanisms and simplifying manufacturing while ensuring long-term contact stability
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
The solution allows for long-term maintenance of contact area and contact surface pressure without requiring precise terminal alignment, reducing stress on terminal roots and enabling high rigidity machining without excessive stress, thus improving the reliability of electrical connections.
Implementation Method 1
applying a plastic deformation with a machine work to an abutted portion
Data Source
AI summary
[Problem]An object of the present invention is to provide the terminal connector and the terminal connection method that are capable of properly keeping the contact area and the contact surface pressure of the electrical contact portion for a long term even if the respective terminals of the motor and the control unit are configured at a simple shape, and to provide the optimum terminal connector and terminal connection method to use for the electric power steering apparatus, the electric actuator and so on.[Means for solving the problem]A terminal connector which connects between a motor-side terminal of a motor and a unit-side terminal of a control unit for the motor, wherein the terminal connector has an electrical contact due to a formation of a junction site between the motor-side terminal and the unit-side terminal by abutting the motor-side terminal and the unit-side terminal and applying a plastic deformation with a machine work to an abutted portion.