Motor-Inverter Terminal Alignment Using Staged Insertion
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Solution Overview
Problem
Existing drive devices for vehicles face alignment issues between motor and inverter units due to manufacturing errors, leading to potential misalignment of terminals and unnecessary stress, or require complex assembly processes without a positioning structure.
Innovation Solution
A drive device design where male and female terminals are configured with varying insertion distances and clearances to facilitate easy alignment and accurate positioning, using reference terminals with tapered or curved shapes to guide assembly, allowing the connection structure to serve as both an electrical and mechanical positioning mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a positioning structure such as a positioning pin is provided between the motor unit and inverter unit, then the alignment between terminals is improved, but the device complexity increases
Solution Approach 1:
The patent merges the positioning function and electrical connection function into a single integrated structure. The male terminals on the inverter unit and female terminals on the motor unit serve dual purposes: they provide electrical connectivity while simultaneously acting as positioning elements that guide alignment during assembly. This eliminates the need for separate positioning pins or fixtures, thereby reducing structural complexity while maintaining manufacturing precision.
Solution Approach 2:
The terminal connectors are designed to perform multiple functions: electrical conduction and mechanical positioning. By making the terminals universal elements that fulfill both roles, the patent avoids adding dedicated positioning structures, thus resolving the contradiction between achieving precise alignment and maintaining simple device structure.
2Device complexity
If the positioning structure is omitted to reduce device complexity, then the device complexity is reduced, but the alignment precision between terminals deteriorates
Solution Approach 1:
The patent combines the positioning and electrical connection functions into the terminal structure itself. The male-female terminal interface serves as both the electrical pathway and the mechanical guide for alignment, eliminating the need for additional positioning components while ensuring precise terminal alignment during assembly.
Solution Approach 2:
The terminal structure is designed to self-align during assembly. The geometric configuration of the male terminals inserting into female terminals automatically provides positioning guidance, allowing the system to achieve precise alignment without external positioning aids or complex fixtures.
3Ease of manufacture
If all male terminals have the same insertion distance to simplify manufacturing, then the ease of manufacture is improved, but the alignment precision during assembly deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the insertion distances of specific male terminals. At least one male terminal has a longer insertion distance than others, creating a staged insertion sequence. This local variation provides self-alignment guidance during assembly, improving alignment precision while maintaining relatively simple manufacturing processes.
Solution Approach 2:
The patent introduces asymmetry in the terminal design by making at least one male terminal longer than the others. This asymmetric configuration creates a natural alignment mechanism where the longer terminal engages first, guiding the relative positioning of the motor unit and inverter unit, thereby improving assembly precision without significantly complicating manufacturing.
Data Source
AI summary
A drive device for a vehicle includes a motor unit including a motor and an inverter unit including an inverter. One of the motor unit or the inverter unit is provided with a plurality of male terminals. The other of the motor unit or the inverter unit is provided with a plurality of female terminals. Each of the male terminals has a columnar shape that extends along the direction of assembly of the inverter unit to the motor unit. Each of the female terminals has a hole into which a corresponding one of the male terminals is inserted along the assembly direction. At least one of the male terminals has a longer distance of insertion into the female terminal than that of the other male terminals.