Electric Compressor Lead Holding Member for Circuit Board Assembly
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Solution Overview
Problem
The assembly of electric compressors is hindered by lead deformation and positional deviations of switching elements, making it difficult to simultaneously insert leads into through-holes on the circuit board, thereby complicating the connection process.
Innovation Solution
The introduction of a lead holding member with lead insertion holes that correct and hold the leads at predetermined positions, allowing for easy alignment and connection, and optionally featuring tapered holes for easier insertion and screw-access openings for fixing screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If switching elements are fixed to the casing first and then the circuit board is assembled, then the assembly process can proceed in a logical sequence, but lead deformation or attachment position errors cause distal end positions to deviate from predetermined positions, making it difficult to simultaneously insert leads into through-holes
Solution Approach 1:
The lead holding member is prepared in advance with lead insertion holes positioned precisely relative to the through-holes. This preliminary positioning structure ensures that even if leads deform during assembly, they will be guided to the correct positions when inserted into the holding member, resolving the contradiction between assembly sequence and position accuracy.
Solution Approach 2:
The lead holding member acts as an intermediary component between the switching elements and the circuit board. It provides a stable reference structure that holds leads at predetermined positions, mediating the connection process and eliminating the direct dependency between lead position and through-hole alignment.
2Productivity
If multiple leads are inserted into different through-holes simultaneously, then connection efficiency can be improved, but lead deformation or positional deviation makes simultaneous insertion difficult
Solution Approach 1:
The lead holding member pre-positions all leads before insertion, so that when assembly occurs, the leads are already aligned with their corresponding through-holes. This preliminary action enables simultaneous insertion of multiple leads without manual alignment, improving both productivity and ease of operation.
Solution Approach 2:
The lead holding member's tapered holes automatically guide and self-align the leads during insertion. The leads themselves serve to align with the tapered holes, eliminating the need for external alignment tools or manual adjustment, thus enabling easy simultaneous insertion.
3Manufacturing precision
If leads are held rigidly to maintain precise positioning, then alignment accuracy improves, but insertion difficulty increases due to lead deformation
Solution Approach 1:
The lead insertion holes are designed with a tapered shape, changing the dimensional parameter from a tight fit at the opening to a smaller diameter at the base. This parameter change allows easy insertion of deformed leads while maintaining precise positioning accuracy once the leads are seated at the narrower base of the tapered holes.
Data Source
AI summary
An electric compressor includes: a circuit board on which a plurality of switching elements (33) are mounted; a compression mechanism which is driven by a motor operated using AC power output from the switching elements (33); and a lead holding member (50) disposed between element main bodies (33a) of the switching elements (33) and the circuit board. The circuit board includes a plurality of through-holes through which a plurality of leads (33b) that extend from the element main bodies (33a) can be respectively inserted. The lead holding member (50) includes lead insertion holes (53) through which the leads (33b) can be inserted such that positions of the leads (33b) is held at positions that correspond to positions of the through-holes.