Forklift Power Element With Elastic Sleeve For Misalignment
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Solution Overview
Problem
Existing power units for industrial trucks face challenges in securely and precisely connecting printed circuit boards to housings, as assembly forces are directly transferred to the internal boards, requiring precise alignment and potentially causing damage from external forces.
Innovation Solution
The power unit employs radially elastically expandable sleeves made of conductive material to clamp contact sections, allowing for misalignment and absorbing external forces, ensuring secure and watertight connections without damaging the internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If connections are mechanically fixed to housing and circuit board by screwing and pressing, then secure mechanical connection is achieved, but assembly forces are directly transferred to internal printed circuit board causing potential damage
Solution Approach 1:
The connection system is segmented into three distinct parts: external connection part, internal contact section, and elastic sleeve. This segmentation allows the mechanical connection to be separated from the circuit board, with the elastic sleeve absorbing assembly forces and preventing them from being directly transferred to the printed circuit board.
Solution Approach 2:
The elastic sleeve acts as an intermediary element between the external connection and the internal circuit board. It absorbs mechanical stresses and forces during assembly, preventing these forces from being directly transferred to the fragile printed circuit board while maintaining secure electrical connection.
2Reliability
If housing and circuit board are manufactured with very high precision for safe and watertight installation, then reliable sealing is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention changes the tolerance parameters of the connection system. By introducing the elastic sleeve and misalignment compensation mechanism, the system can accommodate larger tolerances in housing and circuit board manufacturing while maintaining watertight sealing and reliable electrical connection, thereby reducing manufacturing precision requirements.
3Reliability
If contact sections are precisely aligned and configured relative to housing opening, then optimal electrical connection is achieved, but assembly complexity increases
Solution Approach 1:
The elastic sleeve provides dynamic adaptation capability, allowing the contact sections to self-align during assembly. The elastic deformation of the sleeve compensates for misalignments between contact sections, eliminating the need for precise pre-alignment and complex assembly configurations while maintaining reliable electrical connection.
4Ease of operation
If misalignment between contact sections is accommodated, then ease of assembly is improved, but contact reliability may deteriorate
Solution Approach 1:
The elastic sleeve functions as a flexible shell that can deform to accommodate misalignments between contact sections. This flexibility allows easy assembly with larger tolerances while the elastic recovery force ensures maintained contact pressure and reliable electrical connection, resolving the trade-off between assembly ease and contact reliability.
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 solution enables force-decoupling of power supply to the printed circuit board, allowing for misalignment and absorbing external forces, thus preventing damage and ensuring reliable electrical contact even with larger tolerances, simplifying the assembly process.
Implementation Method 1
A radially elastically expandable sleeve made of conductive material clamps around both contact sections, the outer contour of the contact sections and the sleeve being shaped in such a way that mechanical contact of the contact sections with the sleeve is maintained even if the contact sections are misaligned with one another
Data Source
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Figure 3
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AI summary
Power section for a motor of a forklift truck, comprising a housing, at least one printed circuit board in the housing having power and control components for the motor, and power connections for the power supply which are passed through a wall of the housing and contacted with the printed circuit board, wherein the power connections have a first connection part passing through the wall with a first contact section located inside the housing, a second connection part in contact with the printed circuit board and with a second contact section which is aligned with and spaced apart from the first contact section, and a radially elastic sleeve made of conductive material which clamps around both contact sections, wherein the outer contour of the contact section and the sleeve are shaped such that mechanical contact of the contact sections with the sleeve is maintained even in the event of misalignment of the contact sections relative to each other.