Integrated Housing Connector for Power Conversion Devices
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Solution Overview
Problem
Power conversion devices that receive power via a power line often increase in size due to the need for external connectors, which complicates connections and increases the risk of power line breaks.
Innovation Solution
A power conversion device design that integrates a housing with a power line introduction hole and a connection terminal within the device, eliminating the need for external connectors and allowing direct connection of the power line, while also incorporating a grommet to prevent water and dust entry and optimizing the layout to reduce size and bending risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a converter-side connector is provided on the outer peripheral surface of the housing to connect the power cable, then the connection between power line and power converter is achieved, but the size of the power conversion device increases due to the connector component
Solution Approach 1:
The connector is merged with the housing structure. The housing includes a connector portion that directly forms the connection interface, eliminating the need for a separate connector component. The power line introduction hole is formed in the housing, and the connector portion is integrated into the housing body, allowing the power cable to be connected directly through the housing without additional external connectors.
2Adaptability or versatility
If a connector is provided on the outer peripheral surface of the housing, then the power line can be connected externally, but the number of components increases and complexity increases
Solution Approach 1:
The connector functionality is merged into the housing structure. The housing includes a connector portion that is formed as an integral part of the housing body, reducing the total number of components. The power line introduction hole and connector portion work together as a unified connection system, eliminating the need for separate connector assemblies while maintaining connection flexibility.
Solution Approach 2:
The housing serves multiple functions: it protects the power converter, provides structural support, and integrates the connection function through the connector portion. The housing acts as both a protective enclosure and a connection interface, reducing the need for additional dedicated connector components.
3Ease of manufacture
If the power line is introduced through a hole perpendicular to the housing surface, then the connection is simple, but the power line may bend and break near the connection terminal
Solution Approach 1:
The power line introduction hole is formed at an inclined angle rather than perpendicular to the housing surface. This asymmetric configuration allows the power line to enter the housing at an angle that reduces bending stress near the connection terminal, improving durability while maintaining manufacturing simplicity.
Solution Approach 2:
The connection geometry is changed from a perpendicular (one-dimensional) arrangement to an inclined (angular) arrangement. The power line introduction hole is formed at a predetermined inclination angle, creating a more favorable geometric path for the power line that reduces bending and improves reliability.
Data Source
AI summary
A power conversion device includes a power converter and a housing to be attached to a motor and to house the power converter. The housing includes a power line introduction hole through which a power line is introduced to supply power from an outside to the power converter. The power converter includes a connection terminal to which a terminal of the power line introduced into the housing through the power line introduction hole is directly connected.