Power Converter Connector Mounting to Reduce Cover Load
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Solution Overview
Problem
Existing power conversion devices face challenges in reducing the load and stiffness of the cover portion due to the reaction force generated when connecting the motor-side and inverter-side connectors, which is difficult to manage with the current configuration.
Innovation Solution
The power conversion device separates the motor connection AC connector's fixation from the cover portion, using a central plate as a connector-fixing portion to receive the reaction force, thereby reducing the load on the cover portion and its stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the motor connection AC connector is fixed to the cover portion, then the connector can be securely mounted, but the reaction force from connector insertion increases the load on the cover portion, making it difficult to reduce cover portion stiffness
Solution Approach 1:
The inverter case is divided into two separate functional parts: the cover portion that contacts the motor-side connector and a support plate that mounts the motor connection AC connector. This segmentation allows the reaction force to be borne by the support plate rather than the cover portion, enabling the cover portion to be made with lower stiffness while maintaining secure connector mounting through the support plate's structural support.
2Weight of stationary object
If the cover portion stiffness is reduced to make the device smaller and lighter, then the device size and weight decrease, but the load on the cover portion from connector reaction force increases
Solution Approach 1:
The support plate acts as an intermediary structure between the motor connection AC connector and the inverter case. It receives and distributes the reaction force from connector insertion, preventing this force from being transmitted to the cover portion. This allows the cover portion to be designed with reduced stiffness for weight reduction while the support plate handles the mechanical loading.
3Reliability
If the motor connection AC connector is strongly pressed against the cover portion for sealing, then the connection seal is improved, but the force received by the cover portion becomes large
Solution Approach 1:
The sealing function is separated from the load-bearing function. The support plate provides the mounting structure that can handle the pressing force for sealing, while the cover portion's contact with the motor-side connector provides the sealing interface. This segmentation allows effective sealing through controlled contact pressure without requiring the cover portion to bear large forces.
Data Source
AI summary
A power conversion device includes: a power module forming at least a part of a power conversion circuit; a motor connection AC connector configured to be connected to a motor-side connector included in a motor; a motor connection bus bar connecting the motor connection AC connector and the power module; a cover portion configured to come into contact with the motor-side connector and covering the power module; and a connector-fixing portion formed into a separate body from the cover portion and to which the motor connection AC connector is fixed.