Positioning Ramp Geometry for Precise Connecting Rail Attachment
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Solution Overview
Problem
Existing cast bodies do not effectively facilitate the translationally precise positioning and fastening of connecting rails to substrates without rotation or contact, particularly in power modules, which is crucial for ensuring electrical insulation and meeting lifetime requirements.
Innovation Solution
A cast body with positioning ramps having specific geometric parameters, including an angle of 40° to 85°, varying widths, and a partially overlapping design above the substrate, allows for translationally precise positioning and fastening of connecting rails without contact, using methods like welding, gluing, or screwing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional positioning ramps are used, then the connecting rail can be positioned on the substrate, but rotation or contact of the connecting rail may occur, reducing positioning precision and reliability
Solution Approach 1:
The positioning ramp is designed with a specific geometric configuration (angle α between 40° to 85°, with a step) that pre-determines the correct placement position and orientation of the connecting rail before fastening occurs. The step structure creates a mechanical stop that prevents rotation and ensures the rail is positioned correctly in advance of the fastening operation.
Solution Approach 2:
Instead of relying on the connecting rail to self-align or using complex adjustment mechanisms, the invention inverts the approach by designing the positioning ramp geometry to actively guide and constrain the rail into the correct position. The ramp angle and step configuration work together to prevent rotation by creating an asymmetric mechanical interface that only accommodates the rail in the correct orientation.
2Manufacturing precision
If the positioning ramp is designed with specific geometric parameters (angle 40° to 85°, varying widths), then translational positioning precision is improved, but the device complexity increases
Solution Approach 1:
The positioning ramp incorporates localized geometric features (specific angle range of 40° to 85°, varying widths from lower to upper end, and a step) only at the critical positioning interface. The rest of the cast body maintains simpler geometry. This localized complexity approach achieves high translational positioning precision without requiring the entire device to be complex.
3Reliability
If the positioning ramp is formed partially above the substrate, then the connecting rail can be positioned without contact, but the manufacturing complexity increases
Solution Approach 1:
The positioning ramp extends partially above the substrate surface, creating a pre-positioning structure that guides the connecting rail into the correct position before the fastening operation begins. This preliminary geometric guidance ensures contact-free positioning, as the rail is directed by the ramp geometry rather than requiring contact with the substrate surface during placement.
Data Source
AI summary
A cast body having at least one positioning ramp for positioning and fastening a connecting rail to a substrate. An angle α of the at least one positioning ramp is 40° to 85°, a width at the lower end of the at least one positioning ramp is greater than a width at the upper end of the at least one positioning ramp, the at least one positioning ramp is at least partially formed above the substrate and the connecting rail is positioned translationally, and preferably without contact, in front of a step of the cast body. A corresponding positioning ramp on a cast body, a method for positioning and fastening using the cast body, and a corresponding use thereof, are also described.