Development of the world's smallest and lightest power pack that can integrate electric power steering motors and ECUs
The widely used EPS (Electric Power Steering System), which was developed based on energy conservation and emission reduction of automobiles, has once again made a new breakthrough. In response to the increasing demand for space-saving and lightweight weight in the automotive market, the development of compact products has been further promoted by integrating ECUs and motors, which are separate from conventional steering drive motors.
The integration of the motor and ECU has played an important role in reducing costs, as it reduces the number of wiring harnesses required for interconnection and eliminates the need to assemble products. In addition, the wiring harness connecting the motor and the ECU has an antenna function, but the antenna can be removed when the motor and ECU are integrated to eliminate the problem of noise interference.
The integration of a split EPS motor with an ECU not only reduces size and weight, but also reduces costs, while also solves the problem of noise interference caused by wiring harnesses.
In order to integrate and improve otherwise independent products, the technical obstacles were obvious.
The first is the issue of heat. The motor itself has to generate heat, and the integrated EPS has no room for heat dissipation, which becomes an obstacle. In addition, ECUs must be miniaturized in conjunction with motors, and the heat dissipation of high-density integrated circuits will be further reduced. In particular, electrolytic capacitors have problems such as large size, heat-induced drying, and electrolyte evaporation. Since heat has a large impact on solder, there is a possibility that microscopic cracks may occur inside under the action of thermal fatigue.
In terms of capacitance, the latest small, low-resistance capacitors have been adopted to achieve miniaturization and high reliability, and a layout plan has been developed to solve the effects of heat and the space footprint. The soldering problem was solved by improving the composition of the material and the shape of the pad.
The problem of heat is a huge difficulty in achieving power integration. By improving the component selection, circuit layout, board type, and pad design of high-density integrated circuits, we finally overcame various difficulties and achieved integration.
In addition to the integration of motors and ECUs, it is necessary to take on the challenge of improving controllability. In order to achieve a more natural generation of torque when assisted by a motor, a control method has been established to minimize cogging effects and torque fluctuations that interfere with steering control and cause vibration and noise.
In order to establish this control method, the integrated EPS power pack is first installed on the test vehicle and the basic actions are repeated to collect data. While exploring the correlation between how motor torque is generated and the feeling of control, we design a logical program that makes it realistic, evaluate it based on tests, and then implement improvements, and this method is constantly repeated.
In addition, in order to achieve a more natural sense of control, torque fluctuations that cause noise and vibration are minimized, and an EPS power pack that integrates the motor and ECU with optimal control parameters has been created.
In addition to the integration, we have tried to establish a control method that can further improve the steering feel, noise, and vibration.
Note from the developer
In addition to thermal and control methods, we have developed an EPS power pack to overcome many challenges, such as the introduction of MR sensors to replace conventional resolvers. In the future, we will need to do our best to deal with autonomous driving. There are many issues that need to be solved urgently, such as fault tolerance in the event of a breakdown and problems when handing over to a person while driving, but the development of automotive technology will not stop, and it is our mission to develop products that respond to market trends. We have built such a high-level system, from parts to modules, to the establishment of module-related control methods, and the challenges that need to be overcome have risen to new heights, and I would like to continue to develop our technology so that our customers can recognize us as a trustworthy partner.
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