Terminal Block Insertion Seal for Compact Motor Controller Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wiring connection structures between rotary electric machines and electric power controllers face assembly errors due to the difficulty in compensating for positional mismatches using plate-shaped bus bars, leading to connection failures and increased structural size when planar seals are used.
Innovation Solution
A wiring connection structure where the electric power controller side terminal block includes a columnar insertion portion that extends into an insertion hole in the casing, allowing for elastic deformation to mitigate assembly errors, and a seal is provided between the insertion portion and the casing to prevent enlargement of the fixing structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a planar seal is provided between the electric power controller side terminal block and the fixing surface of the casing, then sealing performance is improved, but the fixing structure is enlarged and assembly complexity increases
Solution Approach 1:
The terminal block is divided into two functional portions: a fixed portion that attaches to the casing and an insertion portion that protrudes through the fixing surface. This segmentation allows the seal to be localized at the insertion hole rather than requiring a large planar seal area, thus maintaining sealing performance while reducing overall fixing structure size.
Solution Approach 2:
The sealing approach transitions from a two-dimensional planar seal on the fixing surface to a one-dimensional linear seal around the insertion hole circumference. This dimensional change allows the seal to be achieved through the insertion portion passing through the insertion hole, reducing the required seal area and fixing structure size.
2Reliability
If the fixed portion of the terminal block is positioned to accommodate assembly error, then assembly error mitigation is improved, but the fixing structure size increases
Solution Approach 1:
Dividing the terminal block into fixed and insertion portions allows the assembly error accommodation function to be localized to the insertion portion rather than requiring the entire fixing structure to be enlarged. The fixed portion maintains its compact size while the insertion portion provides the necessary adjustment capability.
Solution Approach 2:
The insertion portion acts as an intermediary element between the fixed terminal block and the external connection. It provides the necessary flexibility and adjustment range to accommodate assembly errors without requiring the fixed portion or overall fixing structure to be enlarged.
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 structure effectively mitigates assembly errors, maintains compactness, and enhances electrical conductivity by allowing for precise alignment and connection of terminals without the need for external fixtures, thus reducing the risk of connection failures.
Implementation Method 1
a seal that is formed of an elastic body is provided in a clearance between an outer circumferential surface of the insertion portion and an inner circumferential surface of the insertion hole
Data Source
AI summary
A wiring connection structure includes a rotary electric machine and an electric power controller. The rotary electric machine has a rotary electric machine side terminal block that holds a rotary electric machine side terminal. The electric power controller includes an electric power controller side terminal block that holds an electric power controller side terminal. The electric power controller side terminal block includes a fixed portion fixed to a fixing surface of a casing in the rotary electric machine or the electric power controller by a fixture, and a columnar insertion portion extending from the fixed portion toward the rotary electric machine side terminal block and inserted in an insertion hole provided to the fixing surface. A seal formed of an elastic body is provided in a clearance between an outer circumferential surface of the insertion portion and an inner circumferential surface of the insertion hole.