Power Control Unit Cable Connection With Conductive Spring Contacts
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Solution Overview
Problem
The existing cable connection structure of power control units in vehicles requires complex assembly and is challenging in narrow spaces due to the need for precise connection of connectors, which complicates the layout and increases the difficulty of connecting power supply cables.
Innovation Solution
A cable connection structure using conductive spring members to connect unit-side and cable-side terminals arranged in an up-and-down direction, allowing for elastic deformation to absorb manufacturing errors and maintain connection without complex assembly, and an annular seal member to prevent water droplets from adhering to the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are connected by inserting pins and fixed by bolting, then electrical connection is achieved, but assembly complexity increases and connection work becomes complicated
Solution Approach 1:
The patent merges the electrical connection function and mechanical fixation function into a single integrated connector structure. The connector simultaneously provides electrical contact through pins and structural support through a unified housing, eliminating the need for separate bolting operations and reducing assembly complexity while maintaining reliable electrical connection.
Solution Approach 2:
The patent employs a nested connector design where one connector is inserted into another connector. The power supply cable connector is inserted into the power control unit connector, creating a nested arrangement that simplifies connection by eliminating the need for separate alignment and fastening operations, thereby reducing assembly complexity while ensuring reliable electrical connection.
2Area of stationary object
If multiple parts are densely arranged in engine room, then space utilization is improved, but connector connection becomes difficult in narrow space
Solution Approach 1:
The nested connector design allows one connector to be inserted directly into another, minimizing the lateral space required for connection operations. This nested arrangement enables connector connection in narrow engine room spaces where traditional side-by-side connector arrangements would be difficult to access and assemble.
Solution Approach 2:
The connector system is segmented into modular components that can be independently positioned and then easily connected. The power supply cable connector and power control unit connector are designed as separate but complementary segments that can be assembled in tight spaces through straightforward insertion movements, improving ease of operation in densely packed engine rooms.
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 configuration simplifies the assembly process by eliminating the need for complex connector connections, improves workability, and allows for a more compact layout by shortening the power supply cable, while preventing water adhesion with a simple sealing mechanism.
Implementation Method 1
a cable-side terminal (20) connected to the power supply cable (13). The unit-side terminal (24) and the cable-side terminal (20) are arranged to face each other in an up-and-down direction at an abutting portion between a lower surface of the power control unit (10) and an upper surface of the motor case (12), and are connected to each other via a conductive coil spring (21)
Data Source
AI summary
The disclosure provides a cable connection structure of a power control unit that can improve the work efficiency of assembling the power control unit. A power control unit 10 is attached to an upper portion of a motor case 12 that houses a motor. The power control unit 10 has a unit-side terminal 24 connected to a power supply passage inside the power control unit 10. The motor case 12 has a cable-side terminal 20 connected to a power supply cable. The unit-side terminal 24 and the cable-side terminal 20 are arranged to face each other in an up-and-down direction at an abutting portion between a lower surface of the power control unit 10 and an upper surface of the motor case 12. The unit-side terminal 24 and the cable-side terminal 20 are connected to each other via a conductive spring member.