Throttle Valve Insert Structure for ESD Testing and EMI Grounding
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Solution Overview
Problem
Throttle valves with plastic housings pose challenges in testing the influence of electrostatic discharge from electric motors on electronic devices, as traditional electrostatic discharge guns cannot access the metal housing, and also hinder the grounding of filter capacitors needed to remove electromagnetic interference.
Innovation Solution
A throttle valve design with a partially exposed electrically conductive insert body and connector allows direct access for electrostatic discharge testing and grounds the electric motor housing via a conductive connector, enabling effective testing and interference removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a plastic housing is used to reduce weight, then the weight of the throttle valve is reduced, but the electrostatic discharge gun cannot access the metal housing for testing
Solution Approach 1:
The housing is segmented into plastic and metal portions, with the metal portion specifically designed to be accessible for electrostatic discharge testing. This allows the overall housing to be lightweight plastic while maintaining a testable metal interface.
Solution Approach 2:
A metal insert or metal portion of the housing acts as an intermediary that provides the necessary electrical conductivity for electrostatic discharge testing, bridging the gap between the non-conductive plastic housing and the testing requirements.
2Ease of manufacture
If a plastic housing is used, then manufacturing cost is reduced, but the filter capacitor cannot be grounded to remove electromagnetic interference
Solution Approach 1:
The housing is divided into plastic and metal sections, where the metal section specifically serves as a grounding path for the filter capacitor. This segmentation allows the housing to be primarily plastic for cost reasons while incorporating metal only where needed for EMI control.
Solution Approach 2:
The housing has different material properties in different locations: plastic in most areas for cost and weight benefits, and metal in specific areas for grounding and EMI control. This local differentiation optimizes both manufacturing cost and electromagnetic compatibility.
3Difficulty of detecting and measuring
If a metal housing is used, then electrostatic discharge testing is straightforward, but the weight of the throttle valve increases
Solution Approach 1:
The housing structure is segmented to include a metal portion that provides testability and a plastic portion that reduces weight. This segmentation allows the system to benefit from both material types without requiring a complete metal housing.
Solution Approach 2:
The metal insert or metal housing portion serves multiple functions: it provides a pathway for electrostatic discharge testing, serves as a grounding path for the filter capacitor, and maintains structural integrity, thereby replacing multiple separate components.
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
Facilitates reliable electrostatic discharge testing and electromagnetic interference mitigation by allowing direct access for testing and grounding, simplifying manufacturing, and reducing costs.
Implementation Method 1
the electrostatic discharge gun shoots the metal housing, and the static electricity generated by the electrostatic discharge gun reaches the electronic device for a simulation test
Implementation Method 2
one end of the electric motor connector is electrically connected to the insert body, and the other end is electrically connected to the electrically conductive housing of the electric motor
Data Source
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AI summary
Disclosed is a throttle valve for a vehicle, the throttle valve comprising a housing (1), an electric motor (2) and an insert (3), wherein the electric motor (2) is accommodated in the housing (1) and is used for driving the opening and closing of an air flow passage of the throttle valve; the insert (3) is partially enclosed in the housing (1) and comprises an electrically conductive insert body (32) and an electrically conductive electric motor connector (31), and the insert body (32) is at least partially accessibly exposed from the housing (1); and one end of the electric motor connector (31) is electrically connected to the insert body (32), and the other end thereof is electrically connected to the electrically conductive housing of the electric motor (2). The structure also implements testing for the performance of an electronic device for the resistance to the electrostatic discharge from a throttle valve in the case of a plastic housing of the throttle valve. In addition, when the throttle valve is connected to an engine, the grounding of a filter capacitor connected to the electrically conductive housing of the electric motor is allowed to further remove the electromagnetic interference generated in the electric motor.