DC Link Capacitor Terminal Block for Tool-Free Alignment
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Solution Overview
Problem
Existing methods for securing terminals of a DC link capacitor to power electronics components in traction inverter systems are complex and require additional fasteners or tools, increasing cost and complexity.
Innovation Solution
A terminal block is used to support the terminals during the fastening process, featuring retention and alignment features that secure the terminals to the traction inverter system housing without additional fasteners or tools, and can be integrated with the capacitor housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing methods for securing terminals are used, then reliable attachment is achieved, but device complexity and cost increase due to additional fasteners and tools
Solution Approach 1:
The terminal block integrates multiple functions into a single component: it provides both mechanical support for the capacitor terminals and the fastening mechanism to contacts. The retention features and alignment features are built into the terminal block itself, eliminating the need for separate fasteners and alignment tools, thus reducing device complexity while maintaining secure attachment
Solution Approach 2:
The terminal block incorporates self-aligning features that automatically position the capacitor terminals correctly during assembly. The retention features engage with the housing to provide self-support during the fastening operation, eliminating the need for external tools or additional fastening components to maintain proper alignment and support
2Reliability
If existing methods for securing terminals are used, then secure attachment is achieved, but manufacturing cost increases due to additional fasteners
Solution Approach 1:
The terminal block combines the support function and fastening function into one integrated component. By incorporating retention features and alignment features directly into the terminal block structure, the design eliminates the need for separate fasteners, reducing the bill of materials and simplifying the manufacturing process while ensuring secure attachment of terminals to contacts
3Device complexity
If terminal block supports terminals during fastening, then assembly complexity is reduced, but additional components are added to the system
Solution Approach 1:
The terminal block serves multiple functions simultaneously: it supports the capacitor terminals, provides alignment features for precise positioning, and acts as the fastening interface to the contacts. By making the terminal block a multi-functional component, the design reduces assembly complexity without requiring additional specialized support components, as the terminal block itself performs all necessary functions
Data Source
AI summary
A capacitor assembly includes a traction inverter system housing and a set of power electronics defining two or more contacts, the set of power electronics mounted within the traction inverter system housing. A capacitor housing containing a capacitor is mounted within the traction inverter system housing. The capacitor includes two or more terminals extending outwardly therefrom and overlapping the two or more contacts. A terminal block is secured to the capacitor housing independent of attachment of the two or more contacts to the two or more terminals. The terminal block is configured to support the two or more terminals during a fastening operation attaching the two or more terminals to the two or more contacts. The terminal block may also be secured to the capacitor housing.