Electric Compressor Position-Adjustment Structure for Press-Fit Assembly
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Solution Overview
Problem
Conventional electric compressors face challenges in achieving high positional accuracy for press-fit connections between electrical components and circuit boards, leading to difficulties in assembly tolerances, reliability, and feasibility in automated assembly lines.
Innovation Solution
An electrical device with a position-adjustment structure that allows for the adjustment of electrical components relative to mechanical components before fixation, using a combination of recesses, grease, and potting material to ensure accurate positioning and reliable connections without the need for precise processing or increased assembly tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If press-fit connection is used to connect electrical components to circuit board, then electrical connection is achieved, but high positional accuracy is required which increases assembly difficulty
Solution Approach 1:
A positioning pin is introduced as an intermediary component between the circuit board and the electrical component. The positioning pin extends through a through-hole in the circuit board and engages with a corresponding hole in the electrical component, serving as a mechanical mediator that ensures accurate alignment and positioning during assembly, thereby enabling reliable press-fit connection without requiring high positional accuracy of the through-hole itself
Solution Approach 2:
The positioning pin is installed in advance into the through-hole of the circuit board before the electrical component is mounted. This preliminary action establishes the correct position and orientation of the through-hole relative to the electrical component's mounting holes, allowing subsequent assembly steps to proceed with standard tolerances rather than requiring high precision throughout the entire assembly process
2Manufacturing precision
If assembly tolerances are reduced to achieve high positional accuracy, then connection accuracy is improved, but it becomes difficult to achieve both positioning of circuit board relative to electrical component and positioning relative to case
Solution Approach 1:
The positioning pin acts as a mediator that decouples the positioning requirements between different assembly levels. By providing a fixed reference point at the circuit board level, it allows the circuit board to be positioned relative to the electrical component independently from how the electrical component is positioned relative to the case, thereby reducing overall assembly complexity
Solution Approach 2:
The positioning function is segmented into discrete elements: the positioning pin as a separate component rather than integrating positioning features directly into the case or electrical component structures. This segmentation allows each component to be manufactured and assembled independently with standard tolerances, reducing the cumulative effect of tolerances
3Manufacturing precision
If positioning structures are added to achieve accurate positioning, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The positioning pin serves multiple functions simultaneously: it provides mechanical positioning, acts as a alignment reference, and facilitates the press-fit connection process. This multi-functionality reduces the need for additional separate positioning structures, thereby improving positioning accuracy without proportionally increasing device complexity
Solution Approach 2:
Instead of providing complex positioning structures throughout the entire assembly, the positioning pin concentrates the positioning function at a specific local point where the through-hole intersects with the electrical component. This localized approach achieves accurate positioning with minimal additional structural complexity
Data Source
AI summary
An electrical device includes two or more electrical components that configure an electrical circuit, at least one or more mechanical component that supports the two or more electrical components and is fixed to the two or more electrical components, and a position-adjustment structure that adjusts positions of the two or more electrical components relative to the one or more mechanical component with the at least two or more electrical components being united together, before the one or more mechanical component is fixed to the two or more electrical components.