Power Module Positioning Structures for Precise Terminal Alignment
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Solution Overview
Problem
Existing power modules face challenges in being accurately positioned and electrically connected to control electronics, leading to issues such as bent or displaced terminals that fail to fit into contact holes on assembly boards.
Innovation Solution
The power module incorporates positioning structures on its side surface that interact with an alignment tool, allowing for controlled vertical and lateral movements to ensure precise alignment and secure electrical interconnection, facilitated by complementary geometries between the module and tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used to connect power modules to assembly boards, then the connection process can be completed, but the alignment precision is insufficient resulting in bent or displaced terminals
Solution Approach 1:
An alignment tool is introduced as an intermediary device between the power module and assembly board. The tool includes alignment structures that engage with positioning structures on the power module, enabling precise positioning during the connection process. This mediator resolves the contradiction by providing the necessary alignment precision without requiring complex manual operations.
Solution Approach 2:
Positioning structures are pre-configured on the power module before the connection process. These structures include features such as ribs or protrusions that engage with corresponding alignment structures on the alignment tool. By preparing these positioning features in advance, the system achieves high alignment precision without requiring complex real-time adjustments during assembly.
2Manufacturing precision
If positioning structures are added to the power module, then alignment precision is improved, but the device complexity increases
Solution Approach 1:
The positioning function is segmented from the main power module body and implemented through separate positioning structures such as discrete ribs or protrusions. These segmented features can be independently designed and manufactured, adding minimal complexity to the overall power module while providing the necessary positioning accuracy for alignment with the assembly board.
3Reliability
If traditional alignment methods are used, then the connection process is simple, but terminal damage occurs due to misalignment
Solution Approach 1:
The alignment tool serves as a mediator that guides the power module into correct alignment with the assembly board before connection. The tool's alignment structures engage with positioning structures on the power module, preventing misalignment and terminal damage. This intermediary step adds minimal operational complexity while significantly improving terminal integrity.
Solution Approach 2:
The alignment tool is used to establish correct positioning before the actual connection operation. By performing the alignment action preliminarily, the system ensures terminals are properly aligned with contact holes before insertion, preventing bending or damage. This preliminary alignment step maintains ease of operation while improving reliability.
Data Source
AI summary
A power module comprising at least one module component is provided. The power module has a side surface. The side surface of the power module comprises positioning structures. At least one of the positioning structures has a geometrical form configured for receiving an alignment tool and further configured for vertically moving the power module when sliding the alignment tool along a lateral direction. Moreover, an alignment tool and a method using the alignment tool for positioning and aligning the power module are provided.