Electrical Connection Structure with Error-Absorbing Plug

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Solution Overview

Problem

Existing electrical connection structures for vehicles with rotating electrical machines and control devices face challenges in workability and vibration resistance due to strict dimensional and positional tolerances, leading to increased costs and potential bending stresses when errors occur.

Innovation Solution

A connection member structure with a first connection portion fixedly fastened to a terminal using a fastening bolt and a second connection portion connected via an insertable/removable plug, allowing for error absorption in both axial and perpendicular directions, thereby preventing bending stresses and improving workability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the connection member is fixedly attached to both terminals using rigid fastening methods, then the connection stability is improved, but the tolerance for dimensional errors and positional deviations becomes too strict, increasing manufacturing cost

Engineering Contradiction:

Improveconnection stabilityVSAvoidtolerance for dimensional errors and positional deviations

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The connection member is divided into a rigid first connection portion (fastened with bolt) and a flexible second connection portion (connected via plug), allowing different connection methods for different portions to balance stability and tolerance absorption

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second connection portion changes its physical state from rigid to flexible by using a plug connection instead of rigid fastening, enabling it to deform and absorb dimensional errors while maintaining electrical connection

Inventive Principle:

Principle #35Parameter changes

2Strength

If the connection member is made rigid to ensure structural strength, then the mechanical strength is improved, but the ability to absorb dimensional errors and positional deviations is reduced, causing bending stress

Engineering Contradiction:

Improvemechanical strengthVSAvoidability to absorb dimensional errors

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

Different portions of the connection member have different mechanical properties: the first connection portion is rigid for strength, while the second connection portion is flexible to absorb errors, creating local quality variation throughout the structure

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The second connection portion transitions from a static rigid structure to a dynamic flexible structure that can deform elastically, allowing it to adapt to dimensional variations without generating excessive stress

Inventive Principle:

Principle #15Dynamics

3Reliability

If strict tolerances are applied to bus bar dimensions and attachment positions, then the vibration resistance is improved, but the workability and ease of assembly are reduced

Engineering Contradiction:

Improvevibration resistanceVSAvoidworkability and ease of assembly

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The flexible second connection portion acts as a pre-designed cushioning element that anticipates and absorbs dimensional errors before assembly, eliminating the need for strict tolerance control and simplifying the assembly process

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS7819707B2Electrical connection structure

Publication Date: 2010.10.26 AISIN AW CO LTD

AI summary

An electrical connection structure that includes a first connection portion of the connection member that is fixedly fastened to the first terminal by a fastening bolt, and a second connection portion of the connection member that is connected to the second terminal through an insertable/removable plug, the first connection portion is fixedly fastened to the first terminal by inserting the fastening bolt through an insertion hole provided in one of the connection member and the first terminal, and fastening the fastening bolt in a fastening hole provided in the other of the connection member and the first terminal, the insertion hole is formed larger than a diameter of a shaft-like portion of the fastening bolt, and an inserting/removing direction of the plug and an axial direction of the fastening bolt are substantially parallel to each other.