Inverter Assembly Alignment Using Centering Pins and Connector Guide
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Solution Overview
Problem
Existing inverters face complex assembly and precise positioning challenges due to the combination of control and driver functions on a single electronic card, leading to hyperstatic and imprecise relative component alignment.
Innovation Solution
An inverter design utilizing two elongated centering elements, such as pins or centering fingers, that pass through calibrated holes in the electronic card, busbar system, and connector guide, aligning the electronic card, connector guide, and busbar system isostatically, ensuring precise and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If control and driver functions are combined on a single electronic card, then device integration is improved, but relative positioning precision between components deteriorates
Solution Approach 1:
The patent introduces a connector guide as an intermediary component between the electronic card and power modules. This guide includes guide holes that precisely define the relative positioning of connectors, acting as a mediator that ensures accurate alignment without compromising the integrated single-card design. The guide holes serve as a reference framework that resolves the positioning precision issue while maintaining integration benefits.
2Device complexity
If multiple components are precisely positioned relative to each other, then assembly complexity increases, but if fewer positioning means are used, then positioning precision deteriorates
Solution Approach 1:
The patent segments the positioning function into distinct elements: the connector guide with its guide holes, the calibrated holes in the electronic card, and the reference part with positioning elements. This segmentation allows each component to contribute to positioning independently, reducing assembly complexity while maintaining precision. The guide holes and calibrated holes work together as separate but coordinated positioning features.
Solution Approach 2:
The connector guide is designed with pre-defined guide holes that establish the positioning framework before final assembly. The reference part includes pre-positioned positioning elements that prepare the assembly structure in advance. This preliminary action ensures that when components are assembled, the precise positioning is already established, reducing the need for complex real-time adjustment during assembly.
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
Achieves precise and simplified alignment of inverter components, allowing a single electronic card to function correctly with other components without additional positioning means, enhancing integration and reliability.
Implementation Method 1
The current sensors are connected to the control board and operate by Hall effect
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
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.