Vehicle Power Converter Housing Segmentation for Harness Automation
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Solution Overview
Problem
The existing vehicle-mounted power conversion devices face challenges in automatic fabrication due to manual harness connection processes, which are cumbersome and prone to damage, and result in increased device size and disassembly complexity.
Innovation Solution
A vehicle-mounted power conversion device design featuring a single integrated housing space with connectors for the control and power module substrates, allowing for easy harness connection and reduced size by positioning the divided case and cover further towards the bottom, eliminating the need for a through hole and simplifying assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the harness is connected through a through hole in the partition wall, then the control substrate and power module substrate can be electrically connected, but the harness may be damaged during drawing and manual operations are required
Solution Approach 1:
The housing is divided into two separate housings (first housing and second housing) without a partition wall with through holes. Each housing contains its respective substrates, and the harness connects them externally without needing to pass through the housing structure, eliminating the risk of damage during assembly
Solution Approach 2:
A support member is introduced as an intermediary component to hold and guide the harness during assembly. This support member facilitates the connection process by providing a structured path for the harness, enabling automatic fabrication while preventing harness damage
2Manufacturing precision
If manual harness connection is performed, then the connectors can be precisely connected, but the fabrication process becomes complex and time-consuming
Solution Approach 1:
The harness is preliminarily fixed to the support member before the actual connection process. This preliminary positioning ensures that the harness is correctly aligned with the connectors from the start, maintaining manufacturing precision while enabling faster automatic assembly operations
Solution Approach 2:
The manual mechanical operation of drawing and connecting the harness is replaced with an automatic feeding and positioning system. The support member with preliminarily fixed harness enables automated handling, increasing productivity while maintaining connection precision through controlled positioning mechanisms
3Ease of operation
If a partition wall with through hole is used, then the harness can be routed between housings, but the device size increases and disassembly becomes complex
Solution Approach 1:
The housing is segmented into two separate housings positioned adjacent to each other without a partition wall. This segmentation eliminates the need for internal through holes and allows the harness to connect externally in a more compact arrangement, reducing the overall device volume while maintaining ease of harness routing
Solution Approach 2:
Instead of routing the harness vertically through a partition wall (one-dimensional path), the harness is routed horizontally between the two adjacent housings (changing to another dimension). This dimensional change allows for a more compact device layout and simpler disassembly process
Data Source
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AI summary
A vehicle-mounted power conversion device which comprises: a control substrate (17) which has connectors (21) for connecting a harness (20); a power module substrate (16) which has connectors (19) for connecting the harness (20); the harness (20), one end of which is connected to the connectors (21) of the control substrate (17), and the other end of which is connected to the connectors (19) of the power module substrate (16), and which electrically connects the control substrate (17) and the power module substrate (16); and a case (11), and a cover (12) which house the control substrate (17), the power module substrate (16), and the harness (20). The housing space between the case (11) and the cover (12) is an integrated space, and the division position of the case (11) and the cover (12) is positioned further toward the bottom wall of the case (11) than the connectors (21) of the control substrate (17), and the connectors (19) of the power module substrate (16). Thus, the manufacture of the vehicle-mounted power conversion device is easily automated, damage to the harness is suppressed, and the size of the device is reduced.