Compact Electric Apparatus Connector Design
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Solution Overview
Problem
The existing electric apparatus designs for hybrid and electric vehicles require two separate connectors for connecting three phases of a motor and a generator to the power drive unit, leading to increased component costs and a larger outer shape due to the need for a connector arrangement that prevents interference with rotating electric machines.
Innovation Solution
The electric apparatus configures three one-side connecting terminals and three another-side connecting terminals arranged side by side, with the connector holding these terminals and connecting them to corresponding conductive terminals of DC-AC converters, allowing for a compact arrangement by offsetting the terminals and using busbars for connections, which reduces the connector's length and prevents protrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate connectors are used for motor and generator connections, then connection reliability is improved, but device complexity and product cost increase
Solution Approach 1:
The patent combines two separate connectors (one for motor, one for generator) into a single integrated connector that holds all six connecting terminals. This merging reduces the number of components while maintaining reliable electrical connections for both rotating electric machines, thereby resolving the contradiction between connection reliability and device complexity.
2Reliability
If six connecting terminals are arranged side by side in a row, then connection reliability is improved, but the connector interferes with rotating electric machines and outer shape increases
Solution Approach 1:
The patent transitions from a one-dimensional linear arrangement of terminals to a two-dimensional grid arrangement (2 rows × 3 columns). This dimensional change allows the terminals to be compactly organized, reducing the connector's footprint and preventing interference with rotating electric machines while maintaining reliable connections.
3Object-affected harmful factors
If connecting terminals are offset in axial direction and arranged in two stages, then interference with rotating electric machines is avoided, but connector protrudes and outer shape becomes large
Solution Approach 1:
Instead of offsetting terminals in the axial direction (one dimension), the patent arranges terminals in a two-dimensional grid pattern on the same plane. This approach avoids axial protrusion while still preventing interference with rotating electric machines, thereby resolving the contradiction between interference avoidance and outer shape compactness.
Data Source
AI summary
An electric apparatus including a connector holding six connecting terminals is provided. Three one-side connecting terminals held by the connector are arranged side by side in a row substantially directly below conductive terminals of three phases of one DC-AC converter. Three another-side connecting terminals held by the connector are arranged side by side in a row at positions offset to a side away from the one-side connecting terminals in an axial direction. Upper-end side connecting parts of the three one-side connecting terminals are set to be lower than upper-end side connecting parts of the three another-side connecting terminals, and are connected to the corresponding conductive terminals above via busbars extending in an up-down direction. The upper end-side connecting parts of the three another-side connecting terminals are connected to corresponding conductive terminals via busbars extending along an arrangement direction of the conductive terminals.