Motor-Driven Compressor Connector Holder Assembly
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Solution Overview
Problem
The assembly of motor-driven compressors is hindered by the risk of breakage in the connection between the connector and the substrate due to load applied through the terminal pin, and bending of component lead wires, which complicates the assemblability and reliability of the electronic components.
Innovation Solution
The integration of the connector with a holder made of plastic, where the circuit substrate is fixed, and the bus bars are connected to the circuit substrate before being integrated with the holder, ensuring that the load from the terminal pin is absorbed by the holder rather than the connector or substrate, thus preventing breakage and bending of lead wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the connector and electronic components are fixed to the base member simultaneously with bus bar and component lead wires insertion, then the assembly structure is stable, but the assemblability deteriorates due to complex simultaneous insertion requirements
Solution Approach 1:
The assembly process is segmented into two independent stages: first fixing the connector and electronic components to the base member, then inserting the bus bar and component lead wires separately. This segmentation eliminates the complexity of simultaneous insertion while maintaining structural stability.
Solution Approach 2:
The connector and electronic components are preliminarily fixed to the base member before the insertion of bus bar and lead wires. This preliminary positioning ensures proper alignment and stability, simplifying the subsequent insertion process.
2Ease of manufacture
If the connector and electronic components are mounted on the circuit substrate in advance, then the assemblability improves, but the reliability deteriorates due to load-induced breakage in soldered connections
Solution Approach 1:
The bus bar connection is extracted from the circuit substrate and relocated to the connector, which is separately fixed to the base member. This extraction eliminates the risk of load-induced breakage in the soldered connections on the circuit substrate, as the mechanical load is now borne by the connector-base member assembly instead.
Solution Approach 2:
The connector serves as an intermediary component between the bus bar and the base member. It absorbs the mechanical load from terminal pin insertion, protecting the soldered connections on the circuit substrate from stress and potential breakage.
3Adaptability or versatility
If the circuit substrate moves relative to the holder during assembly, then the assembly flexibility increases, but the manufacturing precision deteriorates due to lead wire bending
Solution Approach 1:
The holder is designed with localized features: a first holding portion that secures the connector and a second holding portion that secures the electronic components. These localized holding features provide precise positioning exactly where needed, preventing relative movement between the circuit substrate, holder, and connected components during assembly.
Data Source
AI summary
Connectors are each integrated with a holder in a state in which bus bars are projected. A first projection and a second projection of the holder are respectively inserted in a first insertion hole and a second insertion hole in a circuit substrate. This determines positions of the holder and the circuit substrate relative to each other. The holder has coil lead wire insertion holes, capacitor lead wire insertion holes, and element lead wire insertion holes. These insertion holes extend in the same direction as the direction in which the bus bars project from the holder.