Terminal Holder for Detachable Motor Controller Assembly
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Solution Overview
Problem
Conventional electric power steering apparatuses with integrated motor and controller units face difficulties in replacing the controller without replacing the entire drive unit, leading to inefficient repair processes and increased production complexities.
Innovation Solution
A drive unit design featuring a motor case, controller case, and terminal holder that allows for easy detachment and reattachment of the controller, enabling separate assembly and replacement of the motor and controller, with electrical coupling achieved through engageable terminals, facilitating efficient repair and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the motor and controller are integrated in one body with welded terminals, then the structural integrity and electrical connection are strong, but the ease of repair deteriorates as the entire drive unit must be replaced when the controller is broken
Solution Approach 1:
The drive unit is segmented into separate motor and controller components that can be independently replaced. The terminal holder design allows the controller to be detached from the motor without damaging electrical connections, enabling selective replacement of the controller while maintaining the motor assembly.
Solution Approach 2:
The terminal holder acts as an intermediary component between the motor terminals and controller terminals. It provides a detachable connection mechanism that maintains reliable electrical contact during operation while allowing easy separation for repairs, resolving the conflict between connection strength and replaceability.
2Device complexity
If the motor and controller are permanently assembled together, then the device complexity is reduced, but the productivity deteriorates due to inability to perform on-site repairs
Solution Approach 1:
The terminal holder provides a dynamic connection system that transitions from a fixed welded state to a detachable state. This allows the drive unit to maintain a simple integrated appearance during operation while enabling quick separation for repairs, thereby improving repair efficiency without significantly increasing device complexity.
Solution Approach 2:
The design allows the controller to be discarded (replaced) independently while recovering and retaining the motor assembly. The terminal holder enables this selective discarding and recovering process, improving productivity by allowing on-site controller replacement without replacing the entire drive unit.
3Reliability
If welded connections are used between motor and controller terminals, then the electrical connection is stable, but the ease of manufacture deteriorates as separate assembly becomes difficult
Solution Approach 1:
The welded mechanical connection system is replaced with a terminal holder-based electrical connection system. This substitution maintains stable electrical connection while dramatically simplifying the assembly process, as terminals can now be connected through the terminal holder without requiring welding operations, improving ease of manufacture.
Data Source
AI summary
A motor includes a stator having a winding wire wound thereon, a rotor, and a shaft. The motor is housed in a motor case, where the motor case has a cylinder part and a bottom part. A first terminal is disposed on the motor case, and has one end coupled to an end of the winding wire, such that the wire passes through a first opening on the bottom part. A controller case is disposed detachably on the bottom part. The controller case has a controller housed therein, and has a second terminal that has one end electrically coupled to a power module and the other end engages with the first terminal to electrically couple the motor and the controller. A terminal holder is attached on the motor case to hold and support the first terminal.