Spring Element for Frequency Converter Coupling
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Solution Overview
Problem
Rigid coupling arrangements in frequency converters can lead to excessive force loading on circuit boards, risking critical failure due to manufacturing tolerances and assembly inaccuracies, and existing solutions complicate assembly processes.
Innovation Solution
A spring element with fastening portions on both the circuit board and coupling arrangement sides, interconnected by a resilient spring portion, is used to absorb positional deviations and distribute forces, preventing excessive loading on the circuit board while allowing for easy assembly by eliminating the need for intermediate elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid coupling arrangement is used to galvanically couple frequency converters, then reliable galvanic coupling is achieved, but excessive force is applied to the circuit board leading to potential failure
Solution Approach 1:
The patent changes the mechanical parameter of the coupling arrangement from rigid to flexible by introducing a spring element. This spring element can deflect within a defined range, allowing the coupling to accommodate positional deviations and manufacturing tolerances without transmitting excessive forces to the circuit board, thus maintaining reliable galvanic coupling while protecting the circuit board from damage
Solution Approach 2:
The coupling arrangement transitions from a static rigid connection to a dynamic flexible connection through the spring element. The spring element can deflect and adapt its position, enabling the system to absorb mechanical stresses and maintain electrical contact reliability under varying conditions without compromising the circuit board
2Stability of the object's composition
If a rigid coupling arrangement with precisely defined position and orientation is used, then stable electrical connection is achieved, but manufacturing tolerances and assembly inaccuracies cause excessive loading of the circuit board
Solution Approach 1:
The patent introduces flexibility by changing the mechanical parameter of the coupling from rigid to spring-based. The spring element can deflect within a defined range, allowing the system to accommodate manufacturing tolerances and assembly inaccuracies while maintaining stable electrical connection, thus decoupling the stability requirement from precise positioning requirements
Solution Approach 2:
The spring element acts as a pre-designed cushioning mechanism that absorbs positional deviations and manufacturing tolerances before they can transmit excessive forces to the circuit board. This beforehand cushioning ensures that even with imprecise positioning, the circuit board is protected from damaging loads
3Adaptability or versatility
If connection cables are used to produce galvanic coupling, then flexible connection is achieved, but assembly complexity increases
Solution Approach 1:
The spring element serves as an intermediary component that combines the benefits of both rigid and flexible connections. It provides the flexibility and adaptability of cable connections while maintaining the structural integration and simplicity of rigid couplings, thus achieving flexible connection without increasing assembly complexity
Solution Approach 2:
The patent merges the advantages of rigid couplings (structural integration, simple assembly) and flexible connections (adaptability, tolerance compensation) into a single spring-based coupling arrangement. This unified solution provides both mechanical simplicity and connection flexibility simultaneously
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
The spring element ensures that the coupling arrangement can be securely attached without causing excessive force on the circuit board, reducing the risk of failure and simplifying the assembly process by allowing the housing to be closed with the spring element already connected, thus maintaining a stable and low-resistance electrical connection.
Implementation Method 1
a spring element, wherein the spring element comprises a fastening portion (44) on the circuit board side and a fastening portion (42) on the coupling arrangement side, said fastening portions (42, 44) being interconnected by a resilient spring portion (46)
Data Source
AI summary
A frequency converter (10a, 10b, 10c) includes a housing (30), a circuit board (12a) arranged in the housing, and a coupling arrangement (20) arranged externally on the housing (30) for galvanically coupling the circuit board (12a) to an adjacently arranged second frequency converter (10b, 10c), wherein the coupling arrangement (20) either comprises a base portion (22) and a coupling member (26) movable with respect to the base portion (22) along a defined movement path, or is formed as a rigid busbar which is designed for simultaneous attachment to the frequency converter and the second frequency converter, and the coupling arrangement (22) is galvanically coupled to the circuit board (12a). The coupling arrangement (22) is connected to the circuit board (12a) by a spring element (40), wherein this spring element (40) has a fastening portion (44) on the circuit board side and a fastening portion (42) on the coupling arrangement side. The fastening portions are interconnected by a resilient spring portion (46).