Electrical Connector Structure for Multi-Directional Tolerance Absorption
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Solution Overview
Problem
Existing electrical connectors face challenges in effectively connecting electric motors to electric power modules due to tolerance issues in the connecting parts and relative positioning, requiring precise length control and additional tooling for fixation.
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, facilitating flexible positioning and connection.
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 independently designed and positioned, eliminating the need for complex tooling to support flexible leads during connection.
Solution Approach 2:
The patent introduces a tolerance-absorbing structure with elongated holes that provide adjustment in multiple directions (X and Y dimensions). This multi-dimensional adjustment capability allows the connector to accommodate positioning tolerances without requiring precise length control of leads or additional tooling support.
2Reliability
If flexible braided leads are used, then electrical connection can be established, but effective connection is difficult to achieve when there is tolerance in connecting parts or relative positioning tolerance
Solution Approach 1:
The patent changes the geometric parameters of the mounting holes from circular to elongated shapes, allowing adjustment in specific directions. This parameter change enables the connector to absorb positioning tolerances in X and Y directions, ensuring reliable electrical connection despite manufacturing variations in busbar positions.
Solution Approach 2:
The tolerance-absorbing structure provides adjustment capability in multiple dimensions through elongated holes oriented in different directions. This multi-dimensional adjustment space allows the connector to compensate for relative positioning tolerances between motor and inverter, ensuring effective connection without requiring high manufacturing precision.
3Manufacturing precision
If precise length control of leads is required, then connection can be achieved, but the connection task becomes more complex and time-consuming
Solution Approach 1:
The electrical connector is designed to be self-aligning and self-adjusting through its tolerance-absorbing structure with elongated holes. The connector automatically compensates for positioning variations during installation without requiring precise pre-control of conductor lengths or additional tooling, significantly improving connection efficiency.
Data Source
AI summary
An electrical connector for electrically connecting an electric motor to an electric power module includes at least one conductor. Each conductor includes a first connecting part, configured to be connected to a motor busbar of the electric motor, and a second connecting part, configured to be connected to a module busbar of the electric power module. The electrical connector further includes a tolerance-absorbing structure arranged on at least one of the first connecting part and the second connecting part on the corresponding conductor. The tolerance-absorbing structure is configured to absorb installation tolerance between the motor busbar and the corresponding module busbar in at least two different directions.