Vehicle Power Supply Insulation Structure for Vibration Resistance
Solution Overview
Problem
Concentrated winding type motors in vehicles face issues with connecting terminals separating due to shock and vibration, leading to potential fractures and increased product defects, especially when insulators are press-fitted with excessive force during assembly.
Innovation Solution
A power supply apparatus with bobbins, a bobbin assembling plate, and a support body, featuring insulators with inclined surfaces and 'T' or 'L' shaped cross sections to facilitate easy insertion of phase electrode terminals, and a connection housing with steps to secure the terminals, reducing the need for excessive force and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulators are press-fitted between phase electrode terminals during assembly, then electrical insulation is achieved, but excessive force is required making assembly difficult and increasing damage risk
Solution Approach 1:
The insulators are pre-installed on the bobbin assembling plate before the phase electrode terminals are assembled. This preliminary positioning allows the terminals to be simply placed onto the pre-positioned insulators without requiring excessive press-fitting force, thereby achieving electrical insulation while maintaining ease of assembly
Solution Approach 2:
The insulators serve as intermediary components positioned between the phase electrode terminals to provide electrical insulation. By pre-positioning these intermediary insulators on the bobbin assembling plate, the assembly process becomes simpler and less forceful while still achieving the required insulation effect
2Ease of manufacture
If connecting terminals are merely press-fitted in slots, then assembly is simple, but terminals separate due to shock and vibration causing fractures
Solution Approach 1:
The connecting terminals are integrated with the bobbin assembling plate through a combined structure where the terminals are formed as integral parts or closely coupled components with the plate. This merging provides both assembly simplicity and connection stability, as the integrated structure resists separation under shock and vibration while maintaining ease of manufacture
Solution Approach 2:
The connection structure utilizes composite construction combining the bobbin assembling plate with connecting terminals in a unified assembly. This composite approach ensures that the connection maintains both simplicity of assembly and reliability under vehicle operating conditions, avoiding terminal separation while keeping manufacturing straightforward
Data Source
AI summary
A power supply apparatus for a vehicle is provided. The power supply apparatus includes a plurality of bobbins around which coils are wounded, a bobbin assembling plate configured to be integrally formed with the plurality of bobbins, a support body configured to support the bobbin assembling plate, a connection housing configured to have a plurality of phase electrode terminals connected to a plurality of connecting terminals, which are installed at one side of an upper end of the support body, and to connect ends of the coils wound around the plurality of bobbins and a plurality of insulators having the plurality of phase electrode terminals alternately disposed sequentially therein and disposed between the plurality of phase electrode terminals, and a housing cover configured to form an outer cover of the connection housing and an outer cover of the support body.