Stress-Free Electrical Contact Alignment for Tolerance Compensation
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Solution Overview
Problem
Existing methods for producing tolerance-compensated connections between components often introduce mechanical forces that can damage the components, and are costly, especially in applications like electric drives where precision is critical.
Innovation Solution
A method involving the controlled movement of one component relative to another in a straight line until electrical contacts align without tension, using optical or force-path measurements to ensure precise contact, and then establishing a detachable connection using screws with dimensions that compensate for tolerances, ensuring no mechanical stress is applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tolerance compensation methods (such as shimming with spacers) are used, then tolerance compensation is achieved, but the process becomes complex and expensive
Solution Approach 1:
The invention extracts the tolerance compensation function from complex mechanical shimming processes and transfers it to the electrical contact system. By using the electrical contacts themselves as the tolerance compensation mechanism, the patent eliminates the need for separate spacers and complex adjustment procedures, thereby reducing device complexity while maintaining manufacturing precision
Solution Approach 2:
The electrical contacts serve multiple functions: they provide electrical connection and simultaneously act as the tolerance compensation mechanism. This multi-functionality eliminates the need for separate compensation components, reducing both device complexity and manufacturing cost while achieving the required precision
2Manufacturing precision
If spring elements are used for tolerance compensation, then tolerance is compensated, but mechanical forces and stresses are introduced into the components which can lead to damage
Solution Approach 1:
The invention replaces the mechanical spring element compensation system with an electrical contact-based compensation system. By allowing the electrical contacts to self-align through their inherent flexibility and the natural clearance in the connection, the patent achieves tolerance compensation without introducing harmful mechanical stresses that could damage welded connections or component structures
Solution Approach 2:
The electrical contacts act as an intermediary element that absorbs tolerance variations through their electrical and minimal mechanical interaction, rather than transmitting harmful mechanical forces to the main components. The contacts serve as a buffer that accommodates dimensional variations without stress transmission
3Reliability
If precise alignment is achieved through controlled movement and measurement, then electrical contacts rest without stress, but the measurement and control process becomes more complex
Solution Approach 1:
The invention employs self-aligning electrical contacts that automatically find their optimal position through controlled movement until electrical contact is established. The system uses simple force-displacement control or optical measurement to detect when contacts meet, allowing the components to self-adjust without complex active control systems, thereby achieving reliable stress-free contact with minimal measurement complexity
Data Source
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AI summary
The invention relates to a method (100) for producing (108) a tolerance-compensated connection between a first component (10) and a second component (14), which method comprises moving (101) the first component (10) relative to the second component (14) in a first direction (40), specifically until electrical contacts (11) of the first component (10) lie against the electrical contacts (15) of the second component (14) with at most only a low level of stress.