Inverter Connector Plate Layout for PCB Alignment in Electric Machines
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Solution Overview
Problem
The existing connection methods for inverter modules in electric compressors face challenges such as misalignment and interference with other components on the printed circuit board during assembly and operation, and require complex procedures and multiple parts, which are inefficient in terms of space utilization.
Innovation Solution
The use of conductive plates with a first and second portion, and an intermediate portion, fixed to the printed circuit board and connector terminals via screws and inserts, which allows for secure and efficient electrical connection without cables, reducing misalignment and enabling automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If threaded bolts are used to fasten connector terminals to the printed circuit board, then electrical connection is achieved, but misalignment and interference with other components occur during assembly and operation
Solution Approach 1:
The connector terminal is segmented into a body portion and a plate portion, where the plate portion extends perpendicular to the PCB surface. This segmentation allows the terminal to maintain stable electrical connection while preventing misalignment with other components on the PCB during assembly and operation.
Solution Approach 2:
The connector terminal transitions from a planar arrangement to a three-dimensional structure where the plate portion extends perpendicular to the PCB surface. This dimensional change enables the terminal to achieve both secure electrical connection and proper spatial alignment with other components.
2Reliability
If traditional connector terminals are used, then electrical connection is established, but the number of parts and assembly steps increases
Solution Approach 1:
The connector terminal integrates multiple functions into a single component: the body portion provides electrical connection while the plate portion provides structural support and alignment. This merging reduces the number of separate parts and simplifies the assembly process.
Solution Approach 2:
The connector terminal serves multiple functions simultaneously: it provides electrical connection, structural support, and alignment reference. This multi-functionality reduces the need for additional components and assembly steps.
3Adaptability or versatility
If lead wires with large bending radius are used, then flexibility is maintained, but space utilization on the printed circuit board is insufficient
Solution Approach 1:
The connector terminal utilizes the third dimension by extending the plate portion perpendicular to the PCB surface. This vertical extension provides necessary flexibility and routing capability without consuming additional planar space on the PCB, thereby optimizing space utilization.
Data Source
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AI summary
The present invention discloses an electric machine (100). The electric machine (100) comprises an electric motor (106) enclosed in a motor housing (104) and an inverter module (114) enclosed in an inverter housing (112) for supplying power to the electric motor (106) from an external power source. The inverter module (114) comprises a printed circuit board (120) having a planar surface (122). The electric machine (100) further comprises a connector (124) mounted over the inverter housing (112) for introducing power from the external power source there through. The connector (124) comprises at least one connector terminal (128, 130). The electric machine (100) further comprises a conductive plate (132, 134), which electrically connects the connector terminal (128, 130) to the inverter module (114).