Electrical Connector With Multi-Directional Tolerance Absorption
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Solution Overview
Problem
Existing electrical connectors face challenges in effectively connecting an electric motor to an electric power module due to tolerance issues in the connecting parts and relative positioning, requiring precise length control and additional tooling for fixing leads.
Innovation Solution
An electrical connector with a tolerance-absorbing structure on its conductors, allowing absorption of installation tolerance in multiple directions through multi-directionally protruding mounting holes or elongated holes, enabling flexible relative positioning and compensation of manufacturing and positioning tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible braided leads are used to establish electrical connection, then the connection can be established between electric motor and electric power module, but the length of leads must be precisely controlled and tooling is needed to support the leads, complicating the connection task
Solution Approach 1:
The electrical connector is divided into separate components: a first connecting part for the motor busbar, a second connecting part for the module busbar, and conductors connecting them. This segmentation allows each part to be optimized independently and simplifies the overall connection process.
Solution Approach 2:
The tolerance-absorbing structure incorporates elongated holes that extend in multiple directions (first direction along the conductor length, second direction perpendicular to it). This multi-directional extension absorbs positioning tolerances in both axial and radial directions, eliminating the need for precise length control and support tooling.
2Reliability
If precise length control of leads is implemented, then effective connection can be achieved, but the connection task becomes more complex and time-consuming
Solution Approach 1:
The connector design changes the dimensional parameters by incorporating elongated holes that extend in multiple directions. This allows the connector to accommodate a range of lengths and positions within the elongated hole dimensions, maintaining reliable connection without requiring precise length control.
Solution Approach 2:
By extending the tolerance-absorbing structure in multiple directions through elongated holes, the design transforms a single-point connection requirement into a multi-dimensional tolerance zone, enabling faster connection while maintaining reliability.
3Adaptability or versatility
If tolerance in connecting parts and relative positioning is accommodated, then easier connection is achieved, but additional tolerance-absorbing structures are needed, increasing device complexity
Solution Approach 1:
The tolerance-absorbing structure with multi-directional elongated holes serves multiple functions: it absorbs positioning tolerances in both axial and radial directions, eliminates the need for precise length control, and removes the requirement for support tooling. This single structure accomplishes what would otherwise require multiple separate features.
Solution Approach 2:
The design merges the tolerance absorption for axial positioning and radial positioning into a single integrated tolerance-absorbing structure with elongated holes that extend in multiple directions, simplifying the overall connector design while achieving comprehensive tolerance accommodation.
Data Source
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AI summary
An electrical connector (10) for electrically connecting an electric motor (20) to an electric power module (30), the electrical connector (10) comprising at least one conductor (100a, 100b, 100c), each conductor (100a, 100b, 100c) comprising: a first connecting part, configured to be connected to a motor busbar of the electric motor (20); a second connecting part, configured to be connected to a module busbar of the electric power module (30); wherein the electrical connector (10) further comprises a tolerance-absorbing structure arranged on at least one of the first connecting part (110a, 110b, 110c) and the second connecting part (120a, 120b, 120c) on the corresponding conductor (100a, 100b, 100c), the tolerance-absorbing structure being configured to absorb installation tolerance between the motor busbar (210a, 210b, 210c) and the corresponding module busbar (320a, 320b, 320c) in at least two different directions.