Motor Wire-to-Board Connector for Compact Frequency Converter Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connections between frequency converters and electric motors are complex and inefficient, particularly in situations with limited space and high installation density, such as in motor systems with parking brakes, PTCs, and fans.
Innovation Solution
A wire-to-board connection system with circular-cylindrical through-openings, conductive contact elements, and pin terminals with spring or screw terminal contacts, allowing for a detachable plug-in connection and centering mechanism, facilitating easy assembly and reduced installation height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional wire-to-board connections are used, then electrical connection between frequency converter and motor is achieved, but the connection becomes complex and requires large installation space
Solution Approach 1:
The connection system is divided into separate modular components: a pin terminal with pin contacts for the frequency converter side, and corresponding receptacles with contact elements for the motor side. These segmented modules can be independently manufactured, tested, and assembled, reducing overall system complexity while maintaining connection reliability through standardized interfaces.
Solution Approach 2:
The pin contacts are inserted into through-openings of the contact elements, creating a nested structure where one component fits within another. This nested arrangement allows for compact design with minimized installation space while ensuring reliable electrical contact through the nested contact interfaces.
2Length of stationary object
If space-saving connection design is implemented, then installation height is reduced, but assembly complexity increases
Solution Approach 1:
The pin terminal and receptacle assemblies are pre-assembled with their respective contact elements and housing components before final installation. The pin contacts are pre-positioned in the pin terminal housing, and the receptacle contact elements are pre-installed in the motor connection housing. This preliminary assembly simplifies the final installation process and reduces assembly complexity despite the compact design.
Solution Approach 2:
The housing elements serve as intermediary components that facilitate the connection between pin contacts and receptacle contact elements. The housing provides structural support, alignment features, and mounting interfaces, making the assembly process easier while maintaining the compact installation height.
3Productivity
If modular pin terminal design is used, then production efficiency is improved, but device complexity increases
Solution Approach 1:
The pin terminal design uses standardized through-openings, contact elements, and housing components that can be universally applied across different motor connection configurations. The same basic modular components serve multiple functions: electrical conduction, mechanical support, alignment, and mounting. This universality enables efficient series production while the modular nature keeps the actual device complexity manageable.
Data Source
AI summary
A motor system includes an electric motor and a frequency converter for controlling the electric motor, wherein the frequency converter has a circuit board with conductor paths. The circuit board is to be electrically connected to the electric motor via a wire-to-board connection. The wire-to-board connection has: through-openings in the circuit board; electrically conductive contact elements which are inserted into the through-openings in the circuit board, which are electrically contacting corresponding conductor paths on the circuit board, and which have through-openings; and a pin terminal having pin contacts, which are to be introduced into corresponding through-openings of the contact elements to form an electrical contact with the contact elements, and which has terminal contacts that are electrically connected to the pin contacts, into which corresponding motor conductors can be introduced in order to electrically connect the motor conductor to a corresponding conductor path of the circuit board.