Bent Bus Bar Terminal Alignment in Electronic Control Devices
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Solution Overview
Problem
In the manufacture of electronic control devices, there is a challenge in accurately aligning the connection terminals of the wiring unit with the electronic components, leading to potential loose connections and excessive force application due to positional deviations.
Innovation Solution
The wiring unit features a conductive member with bent bus bar terminals that engage with a molding die during insert molding, ensuring precise positioning and reducing positional deviations, while the integrated circuit's lead is directed away from the basal plane for easier connection to the bus bar terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the connection terminal of the wiring unit and the terminal of the electronic component are positioned with significant deviation from predetermined positions, then the manufacturing process becomes simpler and faster, but the connection reliability deteriorates due to difficult coupling
Solution Approach 1:
The bus bar terminal is bent in advance during the molding process to extend in a first direction intersecting the basal plane, creating a predetermined positioning structure that ensures accurate alignment with the electronic component terminal before the connection process, thereby preventing positional deviation while maintaining manufacturing efficiency
Solution Approach 2:
The bus bar terminal is bent to extend in a direction intersecting the basal plane (vertical dimension) rather than remaining in the plane, allowing the terminal to reach the electronic component from a different spatial dimension and compensate for positional deviations in the horizontal plane
2Ease of operation
If the lead of the integrated circuit is directed away from the basal plane, then the connection process becomes easier and more accessible, but the structural complexity of the wiring unit increases
Solution Approach 1:
The lead of the integrated circuit is pre-directed away from the basal plane during assembly, positioning it for optimal accessibility and connection with the bus bar terminal, thereby simplifying the subsequent connection process while the overall structural complexity remains manageable through integrated design
3Reliability
If the bus bar terminal is bent to extend intersecting the basal plane, then the positional deviation is reduced and connection reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The bus bar terminal is bent to extend in a first direction intersecting the basal plane during the molding process, creating a predetermined positioning structure that compensates for potential positional deviations and ensures reliable connection, thereby reducing the actual positioning precision requirements during assembly
Solution Approach 2:
By bending the bus bar terminal to extend in a direction intersecting the basal plane rather than remaining within the plane, the design creates a three-dimensional positioning mechanism that tolerates horizontal positional deviations while maintaining vertical alignment, thereby reducing the stringency of manufacturing precision requirements
Data Source
AI summary
An electronic control device includes a wiring unit made from a resin material and an integrated circuit placed on the wiring unit. The wiring unit has a conductive member partially buried therein and including a bus bar terminal and a wiring part extending along a basal plane. The bus bar terminal is bent to extend in a first direction intersecting the basal plane. The integrated circuit includes a lead directed away from the basal plane and connected to the bus bar terminal.