Terminal Block Positioning Structure for Electrified Drive Units
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Solution Overview
Problem
The existing terminal block positioning methods in electrified vehicles, which rely on separate pins and holes, suffer from reduced positioning accuracy due to backlash and tolerances, leading to increased relative positional deviations between the bus bar and the electric motor and power control device.
Innovation Solution
The terminal block is positioned by fitting its main body, which is integrally fixed with the bus bar, into a hole in the case that matches the shape of the main body, eliminating the need for separate pins and holes and thereby improving positioning accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate positioning pins and holes are used to position the terminal block, then the terminal block can be positioned in the case, but the positioning accuracy is degraded due to backlash and tolerances
Solution Approach 1:
The patent merges the positioning function directly into the terminal block main body by forming a positioning protrusion that fits into a positioning groove on the case. This eliminates the need for separate positioning pins and holes, thereby removing the backlash and tolerances associated with separate components while maintaining positioning accuracy. The bus bar is integrally fixed to this streamlined main body, ensuring accurate relative positioning between the bus bar and the case.
2Manufacturing precision
If separate pins are provided at both ends of the fixed base for positioning, then the terminal block can be positioned, but the backlash including tolerances increases and the relative positional deviation amount between the bus bar and the electric motor and power control device increases
Solution Approach 1:
The positioning protrusion is formed as an integral part of the terminal block main body, eliminating separate positioning components. This reduces the number of interfaces and potential sources of backlash, thereby improving manufacturing precision and reducing relative positional deviation between the bus bar and connected components.
Solution Approach 2:
The positioning function is extracted from separate pins and integrated directly into the main body structure through the positioning protrusion. This simplifies the overall structure while maintaining the essential positioning capability, reducing both component count and potential sources of positional error.
3Ease of operation
If a fixed base is connected to the case via a surface seal, then the electric motor can be sealed in the case, but it is difficult to position the fixing base
Solution Approach 1:
The positioning protrusion and groove form an integrated positioning system that combines sealing and positioning functions. The positioning groove is formed on the case surface, and the positioning protrusion on the terminal block fits into it, providing both accurate positioning and sealing contact in a single integrated feature, eliminating the difficulty of positioning separate fixing bases.
Data Source
AI summary
A case in which a terminal block having a main body to which an electric motor is connected at one end side and a bus bar to which a power control device is connected at the other end side is integrally fixed is installed has an opening that matches the shape of the main body, and a hole into which the main body is fitted is formed. As a result, the terminal block is positioned by fitting the main body into a hole formed in the case and having an opening that matches the shape of the main body of the terminal block. By positioning with the main body integrated with the bus bar, it is possible to reduce the relative positional deviation amount between the bus bar and the electric motor or the power control device. Therefore, it is possible to improve the positioning accuracy of the terminal block.