Power Converter Inductor Mounting Without Cable Bundling
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Solution Overview
Problem
Current power converters require lengthy installation times and high manufacturing costs due to complex cable arrangements and the need for manual bundling and fastening of cables with external inductors.
Innovation Solution
A power converter design that integrates an inductor apparatus with a housing and circuit board, using a connection piece to physically and electrically connect the inductor to the housing, eliminating the need for external cables and manual bundling, and incorporating a heat dissipation structure to manage thermal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If external cables are used to connect the inductor apparatus to the power converter, then the inductor can be connected externally, but the cable arrangement becomes complex and manual bundling is required
Solution Approach 1:
The patent merges the cable connection function with the inductor apparatus housing by integrating a connection terminal directly into the housing structure. This eliminates the need for separate external cables and manual bundling operations, as the inductor apparatus connects directly to the power converter through the integrated terminal.
Solution Approach 2:
The housing of the inductor apparatus serves multiple functions: it protects the inductor, provides structural support, and incorporates the connection terminal for electrical connection. This multi-functional design eliminates the need for separate cable management components.
2Reliability
If manual cable arrangement and fastening is performed, then proper connection is achieved, but installation time increases
Solution Approach 1:
The connection terminal is pre-integrated into the inductor apparatus housing during manufacturing. This preliminary action eliminates the need for manual cable arrangement and fastening during installation, as the connection is already prepared and structured for direct attachment to the power converter.
Solution Approach 2:
The inductor apparatus is designed to be self-connecting through its integrated connection terminal. The structure automatically provides the connection interface without requiring external manual intervention for cable management, enabling quick plug-and-play installation.
3Reliability
If cables are led out from the inductor apparatus, then electrical connection is possible, but the cables need to be bundled and fastened manually
Solution Approach 1:
The electrical connection function is merged with the housing structure by integrating the connection terminal directly into the housing. This eliminates the need for separate cables that would require bundling and fastening, as the housing itself serves as the connection interface.
Solution Approach 2:
The patent extracts the cable function entirely from the design and replaces it with an integrated connection terminal in the housing. This extraction eliminates the need for cable bundling and fastening operations, simplifying the manufacturing and assembly process.
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
This design reduces installation time, improves assembly efficiency, and lowers labor and material costs by simplifying the connection process and integrating heat management within the power converter.
Implementation Method 1
a heat dissipation structure is further provided on an outer side of a surface of the housing, and the heat dissipation structure partially or completely surrounds the inductor apparatus, and is thermally connected to the power device, to dissipate heat for the power device
Data Source
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AI summary
This application discloses a power converter. The power converter includes a housing, a power device, a circuit board, a connection piece, and an inductor apparatus. The power device is installed on the circuit board, and an accommodation cavity is formed in the housing and is configured to accommodate the circuit board and the power device. A through-hole is provided on a surface that is of the housing and that faces the circuit board. The inductor apparatus is completely or partially exposed outside the housing and covers the through-hole. The connection piece extends from the circuit board in the housing to the inductor apparatus, and passes through a surface of the housing, to physically connect the inductor apparatus to the housing and electrically connect the power device to the inductor apparatus at the same time. It is easier to install an inductor on the power converter. The inductor apparatus can pre-position cables, and the cables in bundles do not need to be manually arranged or bundled, so that duration for a worker to assemble the inductor can be shortened, assembly efficiency can be improved, and labor costs can be reduced.