Electrical Connector Assembly for Tolerant Conductor Alignment
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Solution Overview
Problem
The existing methods for assembling heavy electrical components on electronic cards in power electronics, such as inverters and DC/DC voltage converters, are inefficient, requiring precise manual or automatic operations and resulting in potential misalignment and increased costs due to the need for precise hole alignment and conductor placement.
Innovation Solution
An electrical assembly with a connector having a mounting part and a connection part, where the connection part's surface width accommodates the axial deviation of the electrical connection conductor, allowing for secure and reliable automatic assembly of heavy electrical components, such as transformers, by enabling the conductor to be soldered onto the connector without precise axial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or automatic operations are used to position electrical connection conductors through holes in the electronic card, then precise alignment can be achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The electrical connector is divided into a mounting part and a connection part, allowing the conductor to be connected to the connection part separately and then mounted as a unit on the electronic card. This segmentation simplifies the overall assembly process while maintaining alignment precision.
Solution Approach 2:
The electrical connector acts as an intermediary component between the electrical connection conductor and the electronic card. It provides a standardized interface that simplifies the connection process, eliminating the need for complex direct alignment between the conductor and card holes.
2Manufacturing precision
If holes are made in the electronic card for passing electrical connection conductors, then proper positioning can be achieved, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The electrical connector is pre-assembled with the electrical connection conductor before mounting on the electronic card. This preliminary assembly allows for easier handling and positioning during the final mounting step, reducing the complexity of the overall manufacturing process.
Solution Approach 2:
The electrical connector serves as an intermediary that simplifies the manufacturing process by providing a pre-prepared connection interface, eliminating the need for complex in-situ assembly operations on the electronic card itself.
3Reliability
If precise alignment operations are performed during assembly, then connection reliability can be ensured, but production time and costs increase
Solution Approach 1:
By segmenting the connector into mounting and connection parts, the design allows for more tolerant alignment during assembly while maintaining reliable electrical connection, thereby increasing assembly speed without compromising reliability.
Solution Approach 2:
The invention changes the geometric parameters of the connector, particularly the dimensions of the connection surface, to accommodate axial deviations of the conductor. This parameter optimization ensures reliable connection even with faster, less precise assembly operations.
4Adaptability or versatility
If the connection surface width is increased to accommodate axial deviation, then assembly tolerance is improved, but the connector size increases
Solution Approach 1:
The connector design applies local quality by providing a wider connection surface only at the specific location where the conductor connects, while keeping other parts of the connector compact. This localized dimension change accommodates axial deviation without significantly increasing the overall connector size.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution facilitates quicker, more reliable, and cost-effective assembly of heavy electrical components, ensuring secure connection and reducing waste, while maintaining electrical insulation safety.
Implementation Method 1
the electrical connection conductor is soldered to the connection surface of the electrical connector
Data Source
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Figure 2
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AI summary
The invention relates to an electrical assembly comprising an electronic card (1), at least one electrical connector (3) and an electrical component (2), the electrical connector (3) comprising a mounting portion (31) and a connection portion (32), the electrical component (2) comprising at least one electrical connection conductor (21), the electronic card (1) having a through-opening (11), the electrical connection conductor (21) extending and passing through the through-opening (11) along a real axis having an axial deviation, relative to a nominal axis, that is less than a predetermined maximum axial deviation, the connection portion (32) of the electrical connector (3) having a connection surface (30) configured to receive the free end of the electrical connection conductor (21), the connection surface (30) having a width greater than a maximum offset of the free end of the electrical connection conductor (21) corresponding to the predetermined maximum axial deviation of the electrical connection conductor (21).