Motor-Inverter Connector Pins for Blind Assembly Alignment Tolerance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge of facilitating the electrical connection between an inverter and an electric motor in electric vehicles, particularly when they are assembled at different times, is difficult due to the complexity of direct connections.
Innovation Solution
A connector system comprising connection elements and pins that allow for easier assembly by enabling a blind connection between the inverter and electric motor, with insulating bodies and flexible tracks to compensate for misalignment and play, allowing separate steps for connecting with the inverter and motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct connection between inverter and electric motor is made, then electrical connection is established, but assembly difficulty increases due to alignment requirements
Solution Approach 1:
A connector is introduced as an intermediary component between the inverter and electric motor. The connector includes connection elements that interface with the electric motor and connection pins that interface with the inverter, serving as a mediator that simplifies the connection process while ensuring reliable electrical contact.
Solution Approach 2:
The connection system is segmented into separate components: connection elements attached to the electric motor, connection pins attached to the inverter, and a housing structure. This segmentation allows each component to be independently positioned and aligned, reducing the overall assembly difficulty compared to a direct rigid connection.
2Adaptability or versatility
If inverter and electric motor are assembled at different times, then manufacturing flexibility is improved, but connection difficulty increases
Solution Approach 1:
The connector serves as a pre-assembled intermediary unit that can be attached to either the inverter or electric motor beforehand. This allows the inverter and motor to be manufactured and prepared separately at different times, then connected through the pre-prepared connector without requiring complex alignment procedures.
Solution Approach 2:
The connection elements and pins are pre-attached to their respective components (inverter or motor) during separate assembly operations. This preliminary action allows the main inverter and motor assemblies to be completed independently, with the final electrical connection being a simpler subsequent step.
3Ease of operation
If flexible connection elements are used, then misalignment compensation is improved, but manufacturing complexity increases
Solution Approach 1:
The connection elements incorporate flexible printed circuit boards (FPC) that can bend and deform to accommodate misalignment between the inverter and electric motor. These flexible circuits provide the necessary compliance while maintaining reliable electrical connection, and can be manufactured using standard FPC fabrication processes.
Solution Approach 2:
The connection system utilizes changes in the physical state and properties of materials, particularly the flexibility and elasticity of the FPC and insulating bodies. By selecting materials with appropriate mechanical properties, the system naturally compensates for alignment variations without requiring complex adjustment mechanisms.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a connector intended to make an electrical connection between an electric motor and an inverter, the connector comprising: - a plurality of connection elements, each connection element being intended to fit with a complementary electrical connection element of the electric motor in order to electrically connect them to each other; and - a plurality of connection pins, each connection pin being electrically connected to one of the connection elements and configured to pass through an orifice provided in a housing of the inverter in order to come into contact with a track of an electrical interconnection bar of the inverter, the orifice being provided in a wall of an inverter casing comprising the inverter.