Battery Terminal Locking Projections for Stud Bolt Alignment
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Solution Overview
Problem
Existing battery terminal manufacturing processes face productivity issues due to rotatable stud bolts and complex part shapes, leading to misalignment and increased manufacturing steps, which result in poor productivity and the need for additional locking members.
Innovation Solution
A battery terminal design featuring a plate portion with a stem hole and locking projections, and a folded side plate portion with head holding features, allowing for early locking of the stud bolt during assembly, reducing manufacturing steps and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the stud bolt is inserted into the stem hole during assembly, then the stud bolt can be positioned, but the stud bolt remains rotatable causing misalignment and poor productivity
Solution Approach 1:
The locking projections are pre-formed on the plate portion before assembly. When the stud bolt is inserted, these pre-existing locking projections immediately engage with the head side faces to prevent rotation, eliminating the need for additional locking steps and ensuring precise alignment from the outset.
Solution Approach 2:
The stud bolt head structure itself incorporates the locking function through its head side faces that engage with the locking projections. The component serves both as the fastening element and the locking element, eliminating the need for separate locking mechanisms and simplifying the assembly process.
2Reliability
If multiple locking members are added to prevent rotation, then the stud bolt can be secured, but the part shape becomes complex and productivity decreases
Solution Approach 1:
The locking function is extracted from a separate locking mechanism and integrated into the plate portion structure itself through the locking projections. This eliminates the need for additional locking members and reduces part complexity while maintaining reliable locking.
Solution Approach 2:
The plate portion serves multiple functions: it provides the stem hole for bolt insertion, forms the locking projections for rotation prevention, and structures the folded side plate portion for head holding. This multi-functionality reduces the total number of components needed.
3Productivity
If the folded side plate portion is added with head holding features, then the stud bolt is locked earlier in the process, but the manufacturing process becomes more complex
Solution Approach 1:
The folded side plate portion with head holding features is pre-formed during plate manufacturing. When assembly occurs, the stud bolt head is already positioned against these pre-formed holding features, enabling immediate locking without additional steps and maintaining simple manufacturing processes.
Data Source
AI summary
An electric wire connecting portion 7 comprises a plate portion 17 and a folded side plate portion 18 continuing to the plate portion 17. This plate portion 17 includes a stem hole 19 for inserting the stem 12 of a stud bolt 4 exclusively, and a plurality of locking projections 20 confront the head side faces 13 of the stud bolt 4. The folded side plate portion 18 includes a folded portion 21 continuing to the plate portion 17, and a head holding portion 22 confronting the head top face 14 of the stud bolt 4 at the folding time. The folded side plate portion 18 is provided, on its two sides and separately of the locking projections 20, with folded side locking protrusions 23 confronting the head side faces 13 of the stud bolt 4. These folded side locking protrusions 23 are provided with notches 27 for inserting and fitting the locking projections 20 therein.