Power Module Alignment Device for Connector Stress Reduction
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Solution Overview
Problem
Conventional power electronic devices face challenges in accurately positioning power modules due to accumulated manufacturing and assembly tolerances, leading to reduced reliability and potential connector damage from mechanical stress, especially when the power module weight increases.
Innovation Solution
An alignment device is introduced, comprising a first connector on the power module, guide rail units on the cabinet sides, a second connector on the rear mounting part, and a guide device that includes a guide post and sleeve for secondary positioning, along with ridges or bumps on the guide rails for primary positioning, to ensure accurate alignment and distribute mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If connectors are aligned by directly interconnecting male and female connectors using guide rails, then the plugging operation is simple, but the positioning precision is insufficient due to accumulated manufacturing and assembly tolerances
Solution Approach 1:
The positioning function is segmented into two independent systems: guide rails for primary positioning and movement guidance, and guide devices (guide posts and sleeves) for secondary precise positioning. This segmentation allows each system to specialize in its function without compromising the other.
Solution Approach 2:
The guide device acts as an intermediary between the guide rail and the connector, transferring and refining the positioning function. The guide post and sleeve mechanism provides the additional precision needed to compensate for guide rail tolerances.
2Power
If power module weight is increased, then the power handling capability is improved, but the mechanical stress on connectors increases causing potential damage
Solution Approach 1:
The guide device performs preliminary positioning and stress distribution before the connector makes full contact. By establishing alignment and distributing weight through the guide post and sleeve mechanism beforehand, the connector is protected from sudden mechanical shock during plugging operations.
3Ease of manufacture
If guide rails are designed for simple structure, then the manufacturing cost is reduced, but the positioning accuracy deteriorates due to accumulated tolerances
Solution Approach 1:
The positioning function is segmented into two independent parts: the simple guide rail structure for primary positioning and movement guidance, and the more precise guide device (guide post and sleeve) for secondary precise positioning. This allows the guide rail to remain simple and easy to manufacture while the guide device provides the necessary precision.
Data Source
AI summary
An alignment device for a power module of a power electronic device is provided, which may be used for aligning the power module while the power module being plugging to or from a rear mounting part of a cabinet of the power electronic device. The rear mounting part is disposed at an inner side of a back plate of the cabinet, the alignment device comprises a first connector disposed on the power module; guide rail units disposed on inner sides of a left side plate and a right side plate of the cabinet; a second connector disposed on the rear mounting part; and a guide device for limiting an offset of the power module moving along the guide rail unit.