AC Connector Rod Assembly Rotational Freedom
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector rod assemblies for power inverter modules in polyphase electric machines face challenges in securely connecting multiple phase leads while allowing for rotational freedom and easy installation, often requiring alignment pins and complex assembly processes.
Innovation Solution
The AC connector rod assembly includes spaced AC connector rods, a carrier plate with snap fingers, and insulating housings that allow each rod to rotate about its center axis, with flexible tabular extensions engaging the housings for secure positioning and simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connector rod assemblies are used, then secure connection of phase leads is achieved, but alignment pins and complex assembly processes are required
Solution Approach 1:
The connector rod assembly performs self-alignment through the interaction between the tabular extension and the slot in the insulating housing. The tabular extension automatically engages with the slot during insertion, eliminating the need for separate alignment pins or complex alignment procedures while ensuring secure connection.
Solution Approach 2:
The slot in the insulating housing acts as an intermediary feature that mediates between the connector rod and the mounting structure. This slot allows the tabular extension to engage and guide the connector rod into proper position, simplifying the overall assembly process while maintaining connection reliability.
2Manufacturing precision
If rigid fixed positioning is used, then precise alignment is achieved, but rotational freedom is restricted
Solution Approach 1:
The connector rod assembly transitions from a static fixed positioning system to a dynamic system that allows controlled rotation. The tabular extension engaging with the slot provides precise alignment during installation, while the design permits the connector rod to rotate about its center axis within the insulating housing, adapting to different installation orientations and operational requirements.
3Reliability
If complex assembly features are added, then connection security is improved, but ease of installation is reduced
Solution Approach 1:
The design extracts and eliminates unnecessary complex assembly features such as alignment pins while retaining the essential connection security function. The simplified structure uses only the tabular extension and slot interaction to achieve both secure connection and easy installation, removing redundant components that complicate the assembly process.
Data Source
AI summary
An electrical system includes an alternating current (AC) connector rod assembly and a polyphase electric machine. The electric machine has a plurality of phase leads each electrically connected to the AC connector rod assembly. The assembly includes spaced AC connector rods each having a center axis. The assembly also includes insulating housings and a carrier plate defining through holes that receive and space the AC connector rods. The carrier plate defines features that engage mating features of the insulating housings while allowing each of the rods to rotate about its respective center axis within the carrier plate. A vehicle includes a direct current (DC) battery pack, a DC bus, an AC bus, a PIM that is electrically connected on a first side to the DC bus and on a second side to the AC bus, the AC connector rod assembly, a traction motor, and a transmission.