Motor Drive Unit Assembly with Integrated Hook Fastening

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Solution Overview

Problem

Conventional motor drive unit assembly structures require separate fastening parts, leading to increased machining costs, poor assembly quality, and longer assembly times due to the need for rotational fastening operations.

Innovation Solution

An assembly structure for a motor drive unit that integrates a heat dissipation fan and heat sink with a base case using hook engagement portions and guide portions to facilitate vertical assembly, eliminating the need for separate fastening parts and preventing wrong assembly, thereby simplifying the assembly process and reducing production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If separate fastening parts such as screws are used to connect the under-cover to the heat sink, then the connection is secure, but machining costs increase and assembly time increases

Engineering Contradiction:
Improveconnection strengthVSAvoidnumber of fastening parts
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent integrates the fastening function directly into the heat sink structure by forming hook-shaped protrusions on the heat sink body. This merging of the fastening function into the main component eliminates the need for separate fastening parts like screws, thereby reducing part count and machining costs while maintaining secure connection through the integrated hook structure that engages with corresponding slots in the under-cover.

Inventive Principle:
Principle #5Merging (Combining)

2Strength

If separate fastening parts such as screws are used to connect PCB assemblies, then the connection is secure, but machining costs increase and assembly time increases

Engineering Contradiction:
Improveconnection strengthVSAvoidassembly time
Core Design Contradiction:
StrengthVSLoss of time

Solution Approach 1:

The patent incorporates fastening protrusions directly into the middle base structure, merging the fastening function with the base component itself. This eliminates the need for separate fastening parts for PCB assemblies, reducing both machining costs and assembly time. The integrated fastening structure allows for quicker assembly operations while maintaining secure connections.

Inventive Principle:
Principle #5Merging (Combining)

3Strength

If a fan cover is used to connect the fan to the heat sink, then the connection is secure, but part costs increase and assembly time increases

Engineering Contradiction:
Improveconnection strengthVSAvoidnumber of coupling parts
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent integrates the fan mounting function directly into the heat sink structure by forming hook-shaped protrusions on the heat sink that engage with the fan housing. This eliminates the need for a separate fan cover, reducing part count and costs while maintaining secure fan attachment. The integrated design simplifies the overall structure by combining the heat dissipation and fan mounting functions in one component.

Inventive Principle:
Principle #5Merging (Combining)

4Strength

If rotational fastening operations are performed to assemble components, then secure connection is achieved, but assembly process time increases

Engineering Contradiction:
Improveconnection strengthVSAvoidassembly process time
Core Design Contradiction:
StrengthVSLoss of time

Solution Approach 1:

Instead of using traditional rotational screw fastening, the patent inverts the approach by using snap-fit hook structures that engage through simple insertion and elastic deformation. The hook-shaped protrusions on the heat sink engage with slots in the under-cover through a straightforward linear motion, eliminating the need for rotational operations and significantly reducing assembly time while maintaining secure connections through the elastic engagement of the hook structures.

Inventive Principle:
Principle #13The other way round (Inversion)

Data Source

PatentEP3352551B1Assembly structure for motor drive unit
Publication Date: 2020.01.29 LSIS CO LTD
  • EP3352551B1 patent drawingFigure 1
  • EP3352551B1 patent drawingFigure 2
  • EP3352551B1 patent drawingFigure 3

AI summary

Disclosed herein is an assembly structure for a motor drive unit. The assembly structure does not require the time for rotating, laying down, or fastening the components during processes of producing it, so that the time required for production can be shortened. In addition, since no separate fastening part is required, the assembly structure can be simplified and the production costs can be reduced. The assembly structure including: a base case (11); a heat dissipation fan (13) comprising a fan (13a) and a housing (13b) arranged outside the fan (13a) to fix the fan (13a), the heat dissipation fan (13) being disposed in an area of an upper portion of the base case (11); a heat sink (12) comprising a base (12a) and at least one side face portion (12b) formed by extending vertically downward from both left and right ends of the base (12a), the heat sink (12) being disposed on one side of the heat dissipation fan (13) on the base case (11); a middle base (14) disposed on the heat sink (12), a power printed circuit board (PCB) assembly (15) disposed on the middle base (14); and a filter PCB assembly (16) disposed over the power PCB assembly (15), the assembly structure comprising: at least one hook fixing portion (17) disposed on an upper surface of the base case (11) to correspond to a position of a front face portion of the housing (13b).