Elastic Connection Terminal for Power Module TIG Welding
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Solution Overview
Problem
The existing connection structure for electric power steering devices requires clamping jigs for TIG welding, leading to increased production costs and a risk of power module breakage due to excessive load, especially when the installation position of connection terminals varies.
Innovation Solution
The element-side connection terminal from the power module includes a first connection terminal portion extending orthogonally and a second connection terminal portion that is bent to provide elasticity, allowing for elastic contact with the counterpart-side connection terminal at a predetermined angle, enabling TIG welding without clamping jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rigid connection terminal structure is used for TIG welding, then the welding process is simple, but the connection terminals cannot accommodate position variations and require clamping jigs
Solution Approach 1:
The connection terminal changes from a rigid structure to a flexible structure by altering its physical parameters (introducing flexibility and elastic deformation capability). This allows the terminal to accommodate position variations without requiring clamping jigs, while still enabling TIG welding through elastic contact between the tip end portions.
2Reliability
If clamping jigs are used to ensure contact during TIG welding, then welding reliability is improved, but production cost increases and the risk of power module breakage increases
Solution Approach 1:
The flexible connection terminal serves itself by using its own elasticity to ensure reliable contact during welding. The terminal autonomously adapts to position variations through elastic deformation, eliminating the need for external clamping jigs and their associated costs and risks.
3Manufacturing precision
If clamping force is applied to ensure terminal contact, then welding accuracy is improved, but the risk of power module breakage increases
Solution Approach 1:
The connection terminal transitions from a static rigid structure to a dynamic flexible structure that can deform elastically. This dynamic capability allows the terminal to achieve precise contact through elastic deformation rather than external clamping force, thereby preventing damage to the power module.
4Device complexity
If a simple straight connection terminal is used, then the structure is simple, but position variations cause void spaces that prevent welding
Solution Approach 1:
The connection terminal's physical parameters are changed by introducing flexibility and elastic deformation capability. This allows the terminal to accommodate position variations and maintain tip end contact alignment without requiring a complex rigid structure with multiple adjustment mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for secure joining of connection terminals without clamping jigs, reducing production costs and minimizing the risk of terminal breakage, while maintaining precise contact and efficient electrical connection.
Implementation Method 1
a second connection terminal portion that is bent at a point before the first connection terminal portion reaches the counterpart-side connection terminal in a direction to obliquely intersect the direction of extension of the counterpart-side connection terminal such that the second connection terminal portion is provided with elasticity and is in an elastic contact with the counterpart-side connection terminal
Data Source
AI summary
An element-side connection terminal (40) extending from a power conversion circuit unit (16) includes a first connection terminal portion (40A) that extends in a direction intersecting a direction of extension of a counterpart-side connection terminal (38); and a second connection terminal portion (40B) that is bent at a point before the first connection terminal portion (40A) reaches the counterpart-side connection terminal (38) in a direction to intersect the direction of extension of the counterpart-side connection terminal (38) such that the second connection terminal portion (40B) is provided with elasticity and is in an elastic contact with the counterpart-side connection terminal (38) at an angle. A tip end side (38T) of the counterpart-side connection terminal (38) and a tip end side (40T) of the second connection terminal portion (40B) are electrically joined.