Pulse Inverter Current Sensor Assembly for Pin Alignment
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Solution Overview
Problem
The assembly of pulse inverters in motor vehicles is challenging due to manufacturing tolerances that can lead to misalignment of contacting pins and measurement pins, making it difficult to establish correct electrical connections between the current measuring device, control board, and contact bar.
Innovation Solution
A current measuring device is designed with movable mounting on the contact bar, allowing for simultaneous orientation and insertion of measurement pins during assembly, followed by secure fastening, which ensures accurate positioning and alignment of the control and measurement pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the current measuring device is rigidly fixed to the contact bar, then the electrical connection is stable, but the assembly process becomes difficult due to misalignment of contacting pins caused by manufacturing tolerances
Solution Approach 1:
The current measuring device is designed with a movable mounting on the contact bar, allowing it to be positioned and oriented freely during assembly. The device can be adjusted to align its contacting pins with the control board's contact openings, and only after proper alignment is achieved is the device secured in its final position. This dynamic approach resolves the contradiction by enabling easy assembly through movement while ensuring stable electrical connection once fixed.
2Reliability
If the contacting pins are precisely positioned to ensure accurate electrical connection, then the connection reliability improves, but the manufacturing complexity increases due to tighter tolerances required
Solution Approach 1:
The current measuring device is equipped with positioning elements such as positioning pins or alignment features that guide the device into the correct position during assembly. These preliminary positioning actions ensure that the contacting pins align with the control board's contact openings before final securing, thereby achieving reliable electrical connection without requiring extremely tight manufacturing tolerances on all components.
3Stability of the object's composition
If the current measuring device is securely fastened to the contact bar, then the connection stability improves, but the ability to adjust and align the device during assembly is reduced
Solution Approach 1:
The mounting system is designed in a dynamic sequence: initially allowing movement and adjustment, then transitioning to a fixed state. The current measuring device can be freely positioned and oriented on the contact bar during the assembly process to achieve proper alignment with the control board. Once the desired position and orientation are achieved, the device is secured to the contact bar using fastening elements such as screws, clips, or adhesive, thereby converting from a movable state to a stable fixed state. This resolves the contradiction by providing adaptability during assembly and stability in the final assembled product.
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 approach simplifies the assembly process by allowing for automatic alignment of pins, reducing the risk of misalignment and ensuring reliable electrical connections, thereby facilitating the production of pulse inverters.
Implementation Method 1
a current sensor with a Hall sensor, by means of which the current strength of the direct current provided by the electronic unit is measured
Data Source
AI summary
A method for producing a pulse inverter comprising a module with electronic components, a contact bar sticking out from a side of the module, a current measuring device arranged on the contact bar, and a control board arranged on the module with a driver circuit, wherein the driver circuit makes contact with the module across control contacting pins of the module and with the current measuring device across measurement contacting pins of the current measuring device, wherein the current measuring device is movably attached to the contact bar, after which the control board is positioned such that the control contacting pins are led through control contact openings of the control board and the current measuring device is displaced such that the measurement contacting pins are led through measurement contact openings of the control board, after which the current measuring device is secured to the contact bar and/or the control board.