Power Converter Bus Bar Mounting for Stable Jig-Free Assembly
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Solution Overview
Problem
The assembly of power converters is hindered by decreased workability due to the need to manually attach bus bars to circuit boards without the use of a jig, leading to instability and potential improper attachment during the assembly process.
Innovation Solution
The design incorporates a second bus bar with a stepped shape and legs that are positioned within a mount in the housing, preventing tipping and allowing for stable attachment without manual holding, and a mount configuration that secures the bus bar, enabling easier and more reliable attachment of the first bus bar to the second bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig is used to attach the bus bar to the circuit board, then the attachment precision is improved, but the device complexity and assembly time increase
Solution Approach 1:
The patent introduces a mount as an intermediary component between the housing and the bus bar. The mount provides positioning protrusions that fit into corresponding recesses on the bus bar, acting as a mediator to ensure precise attachment without requiring complex jigs. This intermediary structure simplifies the overall assembly process while maintaining high precision.
Solution Approach 2:
The bus bar is pre-equipped with positioning protrusions and recesses during manufacturing, allowing it to be directly positioned on the mount without requiring additional alignment tools or jigs during assembly. This preliminary preparation of positioning features enables precise attachment to occur automatically during the assembly process.
2Adaptability or versatility
If manual holding is required during bus bar attachment, then the attachment flexibility is improved, but the workability and assembly efficiency decrease
Solution Approach 1:
The bus bar and mount are designed with self-positioning features where positioning protrusions on the bus bar automatically fit into positioning recesses on the mount. This self-service mechanism eliminates the need for operators to manually hold and position the bus bar, allowing the components to self-align and self-position during attachment, thereby significantly improving assembly efficiency.
Solution Approach 2:
The mount serves as a mediator that provides fixed positioning references through its recesses, allowing the bus bar to be attached without manual intervention. The intermediary structure translates the need for precise positioning into a simple drop-in or snap-fit action, maintaining flexibility while boosting productivity.
3Manufacturing precision
If the bus bar is attached outside the housing using a jig, then the attachment precision is improved, but the assembly time and process complexity increase
Solution Approach 1:
The positioning protrusions and recesses are pre-formed on the bus bar and mount during manufacturing, enabling precise attachment to occur directly within the housing during final assembly. This preliminary preparation eliminates the need for separate pre-assembly steps outside the housing, reducing overall assembly time while maintaining precision.
Solution Approach 2:
The mount acts as an intermediary that enables precise attachment to occur in-situ within the housing. By providing fixed positioning references inside the housing, the mount eliminates the need to attach the bus bar outside the housing and then move it inside, thereby reducing assembly time and process steps.
4Device complexity
If no support structure is provided for the bus bar, then the device simplicity is improved, but the attachment stability and reliability decrease
Solution Approach 1:
The mount serves as a simple yet effective intermediary support structure between the housing and the bus bar. It provides stable positioning through recesses that receive the bus bar's protrusions, ensuring reliable attachment without adding complex support mechanisms. The mount's simplicity maintains device elegance while its functional design ensures high attachment stability.
Solution Approach 2:
The support function is segmented into the separate mount component rather than being integrated into the housing or bus bar structures. This segmentation allows the mount to be optimized specifically for providing stable positioning and support, improving reliability while keeping the overall device structure simple and modular.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A power converter (100) includes a circuit board (4), a smoothing capacitor (3a), a housing (5), a first bus bar (6), and a second bus bar (7, 207). The housing (5) includes a mount (51, 251) including a bottom (51a), a first standing wall (51b), and a second standing wall (51c). The second bus bar (7, 207) includes a first leg (73) configured to prevent the second bus bar (7, 207) from tipping over by being fitted in between the first standing wall (51b) and the second standing wall (51c), and a second leg (74, 274) configured to prevent the second bus bar (7, 207) from tipping over by coming into contact with the bottom (51a).