Adjustable Generator Terminal Box Orientation

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Solution Overview

Problem

Existing generator set terminal boxes have limited space, require external mounting of control components, and offer limited design flexibility due to fixed mounting orientations, increasing complexity and cost.

Innovation Solution

A one-piece terminal box with adjustable mounting orientations and integrated shelves, allowing for flexible placement of components and efficient use of space, featuring a structural member with a wider end for increased component housing and adjustable orientation for different worksite requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a two-piece terminal box is used, then the terminal box can be assembled, but the complexity and cost of assembling the terminal box increases

Engineering Contradiction:

Improveterminal box assemblyVSAvoidterminal box structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges two separate half-shells into a single one-piece terminal box structure. This eliminates the need for assembly between multiple parts, reducing both manufacturing complexity and assembly cost while maintaining the functional enclosure space for electrical components.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If a fixed orientation terminal box is used, then the terminal box structure is simple, but the design flexibility for different worksite requirements is limited

Engineering Contradiction:

Improvemounting orientation flexibilityVSAvoidterminal box mounting system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent introduces a rotatable mounting mechanism that allows the terminal box to be rotated between horizontal and vertical orientations. This dynamic adjustment capability provides design flexibility for different worksite requirements without significantly increasing structural complexity, as the rotation feature is integrated into the mounting brackets.

Inventive Principle:

Principle #15Dynamics

3Volume of stationary object

If a single-piece terminal box is used, then the assembly complexity is reduced, but the internal space for mounting control components is limited

Engineering Contradiction:

Improveinternal component spaceVSAvoidterminal box structure

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

The patent incorporates shelves and mounting brackets as integrated nested structures within the one-piece terminal box. These internal shelves are built into the single-piece construction, providing multiple mounting surfaces for control components while maintaining the simplicity of the overall one-piece structure and avoiding the need for separate assembly parts.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS9444304B2Generator set having adjustable terminal box

Publication Date: 2016.09.13 CATERPILLAR INC

AI summary

A terminal box for a generator set is disclosed. The terminal box may include a generally open structural member configured to be mounted to a generator barrel of the generator set. The structural member may have a first end and a second end that is wider than the first end. When the structural member is mounted to the generator barrel in a first orientation, the second end may be located at a first position relative to the generator set. When the structural member is mounted to the generator barrel in a second orientation, the second end may be located at a second position relative to the generator set.