ELECTRONIC COMPONENTS
Product Details
AMD Busbar
The AMD busbar is a part for transmitting a current from the inverter to the accessory battery. The AMD busbar is sandwiched between 2 resin molded parts for contact protection. The cap and the resin body are constituted integrally by employing a hinge structure.
Product Details
Sensor Housing
The sensor housing is an important part serving as the base of a current sensor (a core part for motor control in an electric motor vehicle) which detects a current flowing in the inverter. It plays a role of outputting a high voltage of several hundred volts and a large current of several hundred amperes to the motor, and insulation performance is required also in a severe use condition. We have realized the 3-motor integrated type (regenerative motor, travelling motor, and 4WD travelling motor), which is the first structure in the world, to contribute to the size reduction of inverters.
Strengths of Sensor Housing
Size Enlargement and Complication of Precision Parts
Due to the employment of the 3-motor integrated type, 10 busbars (a steel plate for large current flow) are insert-molded. Since the dimensional accuracy has a great influence on the sensor performance, enlargement and complication of the shape has progressed, but it was still necessary to manufacture sensor housings with high accuracy. We have repeatedly verified shapes for restraining deformation due to resin molding shrinkage using flow analysis, and have optimized the location and the number of gates (resin inflow ports) and the molding conditions. As a result, we have realized manufacturing which satisfies desired dimensional accuracy also in large and complex parts.
Tailor Welded Blank (TWB) Using Electron Beam Welding
We have realized Tailor Welded Blank (TWB) of the material having a plate thickness of 1.5 mm and the material having a plate thickness of 0.8 mm by electron beam welding. In electron beam welding, the energy density is high, the bead width is narrow, and the thermal influence is low. Therefore, the dimensional accuracy after welding is very high. The conversion rate to thermal energy is 90% which is high, and electron beam welding is performed in vacuum. Accordingly, it is possible to perform welding causing very little sputters (metal particles scattering at the time of welding) and voids (air bubbles), and it is very high quality welding.
Product Details
Relay Terminal Block
The relay terminal block is a part on which the relay for controlling a current input to the onboard charger is mounted. In order to prevent overheating of the relay, the relay terminal block includes a wide heat dissipation surface for releasing heat.
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