Reactor Grip Structure for Vibration-Resistant Assembly Fixation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reactor assemblies in high-frequency applications, such as hybrid and electric vehicles, tend to vibrate violently, leading to potential detachment from the case due to installation constraints, and existing solutions require enlarging the case to ensure fixation.
Innovation Solution
A reactor design that includes a grip member extending in the depth direction of the case, with a screw member fixing the grip member to the bottom plate portion, allowing for firm assembly fixation without enlarging the reactor, and utilizing resin molded portions for integration and protection, while maintaining magnetic characteristics and reducing installation area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reactor assembly is fixed using existing methods, then the assembly can be secured in the case, but the case size must be enlarged to accommodate the fixation structure
Solution Approach 1:
The grip member is nested within the case interior space, utilizing the depth direction of the case rather than requiring additional lateral space. The first and second pieces of the grip member sandwich the assembly from opposite sides, with the connecting piece fitting within the case depth, thereby securing the assembly without enlarging the case footprint.
Solution Approach 2:
The fixation mechanism transitions from a planar arrangement to a three-dimensional configuration by utilizing the depth direction of the case. The grip member extends in the depth direction with pieces positioned at different depths to contact the assembly, effectively using the third dimension (depth) to achieve secure fixation without increasing the case's planar dimensions.
2Productivity
If the reactor is designed for high-frequency operation, then the reactor can meet performance requirements, but violent vibration occurs causing assembly detachment
Solution Approach 1:
The grip member is pre-installed in the case before the assembly is placed, creating a preliminary restraining structure. When the assembly is inserted and the grip member engages with it, the assembly is immediately constrained against vibrational detachment, providing preliminary anti-action against the harmful vibrational forces that occur during high-frequency operation.
Solution Approach 2:
The grip member acts as an intermediary element between the case and the assembly. It transfers and distributes the mechanical constraints from the case to the assembly, mediating the interaction between these two components and providing stable fixation that can withstand the violent vibrations generated during high-frequency reactor operation.
3Reliability
If the assembly is securely fixed to prevent detachment, then reliability improves, but the installation area increases
Solution Approach 1:
The grip member functions as a thin-walled structural element that provides substantial mechanical constraint and fixation capability despite its minimal material thickness. This thin-film approach allows the grip member to securely hold the assembly while occupying minimal space within the case, thereby maintaining small installation area while achieving reliable fixation.
Data Source
AI summary
A reactor includes an assembly formed by assembling a coil and a magnetic core, a case for accommodating the assembly inside, a grip member for sandwiching the assembly from the bottom plate portion side and the opening side inside the case, and a screw member for fixing the grip member to the bottom plate portion by penetrating into the case from outside of the bottom plate portion. The grip member includes a first piece to be held in contact with a surface of the assembly on the opening side, a second piece to be held in contact with a surface of the assembly on the bottom plate portion side, and a third piece connecting the first piece and the second piece in a depth direction of the case.