Inverter Assembly Alignment Using Dual Centering Pins
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Solution Overview
Problem
The assembly of inverters is complex due to the need for precise relative positioning of multiple components, particularly when combining the functions of control and driver boards onto a single circuit board, which complicates alignment and retention of components such as power modules, busbar systems, and current sensors.
Innovation Solution
The use of two elongate centering elements, which are parallel and spaced, rigidly connected to the inverter casing, ensures precise alignment and orientation of the circuit board, connector guide, and busbar system by passing through calibrated holes, eliminating the need for additional positioning aids and allowing for a single circuit board to combine control and driver functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple separate circuit boards are used for control and driver functions, then component positioning is simpler, but device complexity and space occupation increase
Solution Approach 1:
The patent combines the control board and driver board functions onto a single circuit board, reducing the number of separate components. This merging is enabled by the precise alignment system using two parallel centering pins that ensure accurate positioning of power modules, busbar systems, and current sensors relative to the integrated circuit board, thereby resolving the contradiction between reducing device complexity and maintaining manufacturing precision.
2Manufacturing precision
If precise positioning aids are added to ensure component alignment, then manufacturing precision improves, but device complexity and number of parts increase
Solution Approach 1:
The patent extracts the positioning function from complex multi-component alignment systems and implements it through a simple, elegant solution: two parallel centering pins rigidly connected to the housing. These pins pass through calibrated holes in the circuit board, connector guide, and busbar system, providing precise alignment without requiring additional positioning aids or complex mechanisms, thus resolving the contradiction between manufacturing precision and device complexity.
Solution Approach 2:
The two centering pins serve multiple functions simultaneously: they align the circuit board with the connector guide, position the busbar system relative to current sensors, and ensure proper orientation of power modules. This multi-functionality eliminates the need for separate positioning aids for each component, resolving the contradiction by achieving high manufacturing precision with minimal additional parts.
3Volume of moving object
If a single circuit board combines control and driver functions, then device compactness improves, but relative positioning of components becomes more complex
Solution Approach 1:
The patent merges control and driver board functions onto a single circuit board, improving inverter compactness. The two parallel centering pins enable this integration by providing a robust alignment system that ensures precise positioning of all components (power modules, busbar systems, current sensors) relative to the integrated circuit board, thereby resolving the contradiction between compactness and alignment precision.
Solution Approach 2:
The two centering pins act as intermediaries between the housing and the various components (circuit board, connector guide, busbar system). They mediate the positioning relationships, ensuring that all components are correctly aligned relative to each other and to the housing, thus enabling the use of a single integrated circuit board without compromising alignment precision.
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 simplifies the assembly of inverters by ensuring correct alignment and positioning of components isostatically, reducing the complexity and number of parts required, while maintaining high integration and precision, thus facilitating the use of a single circuit board without additional positioning aids.
Implementation Method 1
The current sensors are linked to the control board, and operate using the Hall effect
Data Source
AI summary
The invention relates to an inverter comprising a casing, a circuit board (3), a power module, a connector guide (10) which is configured to keep male connectors of the power module in a given orientation, and a busbar system (6) connected to the power module (4) and comprising a ferromagnetic element (14) that is suitable for interacting with a current sensor (9) that is rigidly connected to the circuit board (3). The inverter (1) comprises two elongate centering elements such as centering fingers or pins (11) which extend in parallel and are arranged at a distance from one another, and are rigidly connected to a reference part of the inverter. In this instance, the two elongate centering elements pass through the circuit board (3), the connector guide (10) and the busbar system (6), with the casing (2) or part of the casing (2) forming the reference part. This ensures that the circuit board (3), the connector guide (10) and the busbar system (6) are correctly aligned with one another.