Winding Component Attachment Structure for Power Conversion Devices
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Solution Overview
Problem
Existing winding component attachment structures, such as those used in power conversion devices for hybrid and electric cars, face challenges in securely fixing reactors with varying outer shape dimensions due to issues with vibration resistance, where either the spring force is too weak for smaller dimensions or excessively strong for larger dimensions, potentially causing detachment or damage.
Innovation Solution
A winding component attachment structure featuring a placing member and a pressing member with adjustable screw positions, utilizing external and internal threads to apply a variable pressing force, along with heat transfer cushioning members to enhance vibration resistance and facilitate heat dissipation, allowing for secure fixation of reactors with different dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a leaf spring is used to press the reactor toward the case, then the reactor is fixed, but the spring force becomes too weak for reactors with small dimensions causing detachment by vibration
Solution Approach 1:
The patent replaces the static leaf spring with a dynamic adjustment mechanism consisting of a pressing member, adjusting member, and screw mechanism. This allows the pressing force to be dynamically adjusted according to the reactor's actual dimensions, ensuring optimal vibration resistance for each specific reactor size.
Solution Approach 2:
The patent changes the fixed spring force parameter to a variable pressing force that can be adjusted according to reactor dimensions. The adjusting member and screw mechanism enable continuous parameter adjustment, transforming the force from a static to a controllable variable.
2Reliability
If a leaf spring is used to press the reactor toward the case, then the reactor is fixed, but the spring force becomes excessively strong for reactors with large dimensions causing damage
Solution Approach 1:
The patent replaces the static leaf spring with a dynamic adjustment mechanism consisting of a pressing member, adjusting member, and screw mechanism. This allows the pressing force to be dynamically adjusted according to the reactor's actual dimensions, ensuring optimal vibration resistance for each specific reactor size.
Solution Approach 2:
The patent changes the fixed spring force parameter to a variable pressing force that can be adjusted according to reactor dimensions. The adjusting member and screw mechanism enable continuous parameter adjustment, transforming the force from a static to a controllable variable.
3Adaptability or versatility
If the reactor outer shape dimensions vary for each product, then different dimensions are accommodated, but the fixed attachment structure cannot adapt leading to either weak or excessive spring force
Solution Approach 1:
The patent creates a universal attachment structure that can accommodate reactors with different dimensions. The adjustable pressing mechanism serves multiple functions: it adapts to various reactor sizes while maintaining reliable attachment, replacing the need for different fixed structures for different reactor types.
Solution Approach 2:
The patent replaces the static attachment structure with a dynamic adjustment mechanism that can adapt to different reactor dimensions. The adjusting member and screw mechanism enable the structure to change its pressing force according to the specific reactor being attached.
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 attachment structure effectively improves vibration resistance and secure fixation of reactors with varying dimensions, while also enabling efficient heat transfer and simplifying the attachment process, ensuring reliable operation in power conversion devices.
Implementation Method 1
heat transfer cushioning members to enhance vibration resistance and facilitate heat dissipation
Implementation Method 2
utilizing external and internal threads to apply a variable pressing force
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
There is provided a winding component attachment structure in which there are fixed, to a case (12), winding components (1A and 1B) each formed by winding a coil (3) around and along an inner peripheral surface and an outer peripheral surface of a ring-shaped core (2) a plurality of times. This structure includes a placing member (13) made of an insulating material and fixed to a fixing surface of the case in a state where a lower surface of the winding component is placed, a pressing member (14) made of an insulating material and disposed to abut on an upper surface of the winding component, and a pressing force imparting portion (15) that couples the placing member with the pressing member and imparts a pressing force toward the fixing surface, from the pressing member to the winding component, and in the pressing force imparting portion, a distance between the placing member and the pressing member is variable in accordance with a height change of the winding component.