Rotary Electric Machine Terminal Block Anti-Vibration Plate
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Solution Overview
Problem
In hybrid motor vehicles, the existing rotary electric machine terminal blocks face challenges in reducing resonance and size while maintaining strength, due to the use of die-cast components that are inferior in strength, leading to vibration and noise issues, and complicating the mounting process.
Innovation Solution
The implementation of a rotary electric machine terminal block with an insert molding process that integrates an anti-vibration plate on a metal presser plate, reducing resonance and sound propagation without increasing component parts, by using a metal presser plate with a projected portion for fixation and a resin anti-vibration layer, and incorporating corrugated protrusions to alter resonance frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If die-cast components are used in the terminal block, then the size can be reduced, but the strength is inferior and resonance occurs
Solution Approach 1:
The terminal block employs a composite structure combining a metal presser plate (providing strength and rigidity) with a resin anti-vibration plate (providing damping and noise reduction). This composite material approach resolves the contradiction by integrating the advantages of both materials: the metal ensures structural integrity while the resin layer suppresses resonance, eliminating the need to choose between size reduction and strength enhancement.
Solution Approach 2:
The resin anti-vibration plate is positioned between the metal presser plate and the connector assembly, creating a nested structure where the resin layer is embedded within the overall terminal block assembly. This nested configuration allows the anti-vibration plate to be integrated without increasing the external dimensions of the terminal block, thus maintaining size reduction while adding strength and vibration suppression capabilities.
2Volume of moving object
If die-cast components are used in the terminal block, then the size can be reduced, but vibration and noise issues occur
Solution Approach 1:
The resin anti-vibration plate converts the harmful vibration and noise generated by the metal presser plate into beneficial damping effects. The resin material absorbs and dissipates vibrational energy, transforming the potential harm of metal resonance into a beneficial noise reduction effect. This resolves the contradiction by maintaining the compact metal structure while eliminating its harmful vibrational characteristics.
Solution Approach 2:
The combination of metal presser plate and resin anti-vibration plate creates a composite structure where the resin layer specifically addresses vibration and noise issues. The metal provides structural support while the resin provides vibration damping, together resolving the contradiction between size reduction and vibration control.
3Object-generated harmful factors
If separate anti-vibration components are added to the terminal block, then vibration can be reduced, but the mounting process becomes complicated
Solution Approach 1:
The resin anti-vibration plate is integrated with the metal presser plate to form a unified terminal block assembly. The anti-vibration function is merged into the structural component itself, eliminating the need for separate anti-vibration parts and simplifying the mounting process. This resolves the contradiction by combining vibration reduction functionality with the existing structural element.
Solution Approach 2:
The composite structure of metal presser plate and resin anti-vibration plate is designed as an integrated assembly where the resin layer is positioned between the metal plate and the connector. This integrated composite design provides vibration reduction without requiring additional separate components or complex mounting procedures.
4Object-generated harmful factors
If separate anti-vibration components are added to the terminal block, then vibration can be reduced, but the number of component parts increases
Solution Approach 1:
The resin anti-vibration plate is merged with the metal presser plate to form a single integrated assembly. By combining the anti-vibration function with the existing structural component, the total number of component parts is reduced. This resolves the contradiction by providing vibration reduction through integration rather than addition of separate parts.
Solution Approach 2:
The resin anti-vibration plate serves multiple functions: it provides vibration damping, noise reduction, and structural support simultaneously. This multi-functionality allows a single component to replace what would otherwise require multiple separate parts, resolving the contradiction between vibration control and component quantity.
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 solution effectively reduces resonance and vibration, enhances the terminal block's strength, and simplifies the mounting process by integrating anti-vibration features within the insert molding process, thereby reducing production costs and component count.
Implementation Method 1
an anti-vibration plate is formed by a resin on an upper surface of the presser plate
Implementation Method 2
the resonance of the presser plate (metal-made plate) of the rotary electric machine terminal block is reduced by the anti-vibration plate
Implementation Method 3
a presser plate provided with a corrugated-shape protrusion for changing a resonance frequency of the terminal block
Data Source
AI summary
A rotary electric machine terminal block fits into an opening of a case that contains a rotary electric machine, and is fixed to the case by a plate. The rotary electric machine terminal block has: a mount that is formed by fixing the electric power line connector and the signal line connector to the steel-made plate and performing insert molding so that an anti-vibration plate is formed on an upper surface of the plate; projected portions of the plate which each have a fixture hole for fixing the plate to the case; an edge seal member that covers an edge of the projected portion; a face seal member for tight attachment of the mount to the case; and two positioning pins.