Power Conversion Device Connection Structure for Vehicle Vibration
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Solution Overview
Problem
As power conversion devices increase in output, the need for a larger conductive area to alleviate heat generation and voltage reduction leads to increased stiffness, making it difficult to maintain flexibility under severe vibration conditions, which is crucial for reliable electrical connections in vehicles.
Innovation Solution
A connection structure for power conversion devices that incorporates an anti-vibration structure for both mechanical and electrical connections, using a flexible electric conductor and waterproof sealing portions to allow relative displacement between the casing and electric connection parts, ensuring flexibility and waterproofness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the conductive area of the electric conductor is increased to handle higher output power, then heat generation and voltage reduction are alleviated, but the stiffness of the harness increases and flexibility decreases
Solution Approach 1:
The electric conductor is divided into multiple independent conductors instead of using a single thick harness. This segmentation allows each individual conductor to remain flexible while collectively providing sufficient conductive area for high power transmission. The multiple conductors can independently accommodate vibrations and displacements.
Solution Approach 2:
The patent uses a composite structure combining multiple conductors with different properties. The conductors are arranged in a specific configuration that combines the electrical conductivity needed for high power with the mechanical flexibility required for vibration resistance. The composite arrangement allows optimal balance between electrical and mechanical performance.
2Temperature
If the conductive area is increased to reduce heat generation, then power transmission capability improves, but the harness becomes stiffer and more difficult to apply under vibration conditions
Solution Approach 1:
Instead of using a single thick conductor that would be stiff, the patent segments the current path into multiple thinner conductors. This segmentation reduces the stiffness of individual conductors while maintaining the total conductive area needed to handle high current with minimal heat generation.
Solution Approach 2:
The harness structure is designed to be dynamic rather than rigid. The multiple conductors are arranged to allow relative movement and deformation under vibration, making the overall system adaptable to mechanical stress while maintaining electrical connectivity and thermal management.
3Reliability
If an anti-vibration structure is added to the electrical connection part, then connection reliability under vibration improves, but manufacturing complexity increases
Solution Approach 1:
The anti-vibration function is merged with the existing harness structure rather than adding separate anti-vibration components. The harness itself is designed with inherent anti-vibration characteristics through its construction method, eliminating the need for additional brackets or fastening mechanisms and simplifying manufacturing.
Solution Approach 2:
The harness structure provides its own anti-vibration protection through its inherent design. The flexible construction and arrangement of multiple conductors allow the harness to self-accommodate vibrations without requiring external anti-vibration devices, reducing manufacturing complexity while maintaining reliability.
Data Source
AI summary
Provided is a connection structure for a power conversion device to be mounted in a vehicle, including: a casing of the power conversion device; an electric connection part, which is to be mechanically connected to the casing, and is configured to electrically connect the power conversion device and an external device to each other; and an electric conductor configured to electrically connect the power conversion device and the electric connection part to each other, wherein the casing and the electric connection part are mechanically connected to each other through intermediation of an anti-vibration structure, and wherein the electric conductor has such flexibility as to be able to follow a relative displacement between the casing and the electric connection part.