Power Conversion Apparatus Frame Rigidity and Vibration Control
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Solution Overview
Problem
The existing power conversion apparatuses in electric vehicles face issues with rigidity, vibration, thermal stress, and maintainability due to non-rigid cases, leading to potential component failure, increased production costs, and unpleasant vibrations.
Innovation Solution
A power conversion apparatus with a high-rigidity case design featuring an internal unit with a frame that secures electronic components and a cooler, reducing external forces and thermal effects, and allowing for easier assembly and maintenance, while minimizing the need for multiple sealing surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electronic components are fixed directly to the case, then assembly is simplified, but the case rigidity decreases and components are susceptible to vibration and thermal stress
Solution Approach 1:
A frame structure is introduced as an intermediary component between the case and electronic components. The frame is fixed to the case and provides a rigid mounting surface for components, while the case itself maintains its lightweight and simple structure. This mediator resolves the contradiction by decoupling the rigidity requirement from the case to the frame.
Solution Approach 2:
The mounting function is segmented from the case structure. Instead of fixing components directly to the case, the frame is segmented as a separate structural element that handles component mounting, while the case focuses on enclosure and sealing functions.
2Reliability
If the case is made rigid to prevent component failure, then component reliability improves, but manufacturing cost increases due to multiple sealing surfaces
Solution Approach 1:
The frame acts as a mediator that absorbs mechanical stress and protects components from thermal expansion forces. The frame's rigid structure provides a stable mounting surface that isolates components from case deformation, while the case can remain simpler with fewer sealing surfaces.
Solution Approach 2:
The thermal expansion parameters of different components are accommodated by the frame structure. The frame is designed to flex or expand differently than the case, creating a buffer zone that protects sensitive electronic components from thermal stress while maintaining overall structural integrity.
3Ease of manufacture
If components are fixed directly to the case, then assembly is easier, but maintainability deteriorates as both lids must be removed for maintenance
Solution Approach 1:
The internal unit is segmented as a removable module that can be accessed independently. The frame and mounted components form a self-contained unit that can be installed or removed as a single assembly, allowing maintenance without removing both case lids. This segmentation improves maintainability while keeping the overall assembly process simple.
4Reliability
If the case has two large sealing surfaces for water-tightness, then sealing performance improves, but the number of sealing members increases and production cost rises
Solution Approach 1:
The frame serves multiple functions: it provides structural rigidity for component mounting, acts as a sealing surface support, and functions as a protective barrier. By consolidating these functions into a single component, the need for multiple separate sealing members is reduced, lowering production costs while maintaining water-tightness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances mechanical and thermal resistance, reduces production costs, and improves maintainability by integrating the internal unit as a beam within the case, thereby minimizing vibrations and thermal stress on components.
Implementation Method 1
a cooler which works to cool at least a portion of the electronic components
Implementation Method 2
a cooler which works to cool at least a portion of the electronic components
Data Source
AI summary
An electric power conversion apparatus is provided which includes electronic components, a cooler, an internal unit, a capacitor, and a case. The internal unit has a frame to which at least one of the electronic components and the cooler are secured and which surrounds all around the one of the electronic components. The frame includes unit fixing sections through which the internal unit is fixed to the case and capacitor fixing sections through which the capacitor is fixed to the internal unit. The capacitor fixing sections are located inward of the frame more than the unit fixing sections. The internal unit is fixed to the case and thus works as a beam to increase the mechanical rigidity of the case. The fixing of the internal unit to the case minimizes external force to be exerted through the case on the electronic component and the cooler.