Motor-Inverter Terminal Layout for Self-Aligning Vehicle Assembly
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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 misalignment of terminals and potential stress, or require cumbersome assembly processes without positioning structures.
Innovation Solution
A drive device design where one unit is equipped with male terminals and the other with female terminals, with at least one male terminal having a longer insertion distance or smaller clearance, allowing for easy alignment and positioning during assembly, and optionally featuring tapered or curved shapes for enhanced alignment.
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 due to additional positioning components
Solution Approach 1:
The patent combines the positioning function and electrical connection function into a single integrated structure. The male terminals with different insertion distances serve dual purposes: they provide the necessary positioning between the motor unit and inverter unit while simultaneously establishing electrical connections, thereby eliminating the need for separate positioning pins or structures.
Solution Approach 2:
The male terminals are designed to perform multiple functions. By making at least one male terminal longer than the others, it serves as both a positioning element (guiding alignment during assembly) and an electrical conductor. This multi-functional design reduces the overall component count and simplifies the structure.
2Ease of operation
If the insertion distance of at least one male terminal is made longer than others, then the alignment during assembly is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The longer male terminal performs preliminary positioning action during assembly. By extending further than the other terminals, it makes initial contact and establishes the correct relative position between the motor unit and inverter unit before the other terminals engage, guiding the assembly process and compensating for minor manufacturing variations.
Solution Approach 2:
The patent introduces asymmetry among the male terminals by making at least one terminal longer than the others. This asymmetric design creates a clear hierarchical engagement sequence during assembly, with the longer terminal serving as a reference that simplifies alignment while the manufacturing tolerances remain standard.
3Device complexity
If a positioning structure is omitted between the motor unit and inverter unit, then the device complexity is reduced, but the alignment between terminals deteriorates leading to misalignment
Solution Approach 1:
The positioning function is merged into the terminal structure itself. The differential insertion distances of the male terminals provide inherent positioning capability without requiring separate positioning components, thus maintaining structural simplicity while ensuring proper alignment.
Data Source
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AI summary
A drive device (10) for a vehicle includes a motor unit (12) including a motor (14) and an inverter unit (20) including an inverter (22). One of the motor unit (12) or the inverter unit (20) is provided with a plurality of male terminals (28a, 28b, 28c, 28d). The other of the motor unit (12) or the inverter unit (20) is provided with a plurality of female terminals (36a, 36b, 36c, 36d). Each of the male terminals (28a, 28b, 28c, 28d) has a columnar shape that extends along the direction of assembly of the inverter unit (20) to the motor unit (12). Each of the female terminals (36a, 36b, 36c, 36d) has a hole (40) into which a corresponding one of the male terminals (28a, 28b, 28c, 28d) is inserted along the assembly direction. At least one of the male terminals (28a, 28b, 28c, 28d) has a longer distance of insertion into the female terminal than that of the other male terminals.