Hybrid Vehicle Bus Bar Clamp with Hinged Retention
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Solution Overview
Problem
Existing bus bar modules in hybrid and electric vehicles have poor workability due to the requirement that the lid of the cable clamp cannot close without first closing the electric wire accommodation part, leading to inefficient operations for accommodating multiple electric wires and retaining cables.
Innovation Solution
A clamp design featuring a clamp base part, hinge part, and clamp moving part with retention parts and partition portions, allowing for simultaneous accommodation of multiple electric wires and cable retention, with the clamp being integrally formed with a resin plate in a bus bar module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lid of the cable clamp cannot close without first closing the electric wire accommodation part, then the structure provides a sequential closing mechanism, but the workability deteriorates due to inefficient operations for accommodating multiple electric wires and retaining cables
Solution Approach 1:
The patent combines the cable clamp and electric wire accommodation part into a single integrated structure where the clamp moving part simultaneously performs both cable retention and electric wire accommodation functions. This merging eliminates the sequential operation requirement, allowing workers to perform both operations at once, thereby improving workability and reducing operational time.
2Productivity
If the clamp design uses separate operations for accommodating electric wires and retaining cables, then the structure provides dedicated spaces, but the operational efficiency deteriorates due to multiple separate operations required
Solution Approach 1:
The clamp moving part is designed as a multi-functional component that simultaneously serves as both a cable clamp and an electric wire accommodation part. This universal design allows a single operation to achieve multiple functions (cable retention and electric wire accommodation), improving productivity while reducing operation complexity compared to separate dedicated components.
Solution Approach 2:
The clamp moving part is divided into multiple retention parts that are positioned between partition portions, creating separate retention spaces for different types of conductors. This segmentation within the unified structure allows dedicated retention for cables and electric wires simultaneously, maintaining organizational clarity while enabling single-operation efficiency.
3Adaptability or versatility
If the clamp moving part is engaged with the clamp base part through hinge part, then the structure provides movable retention parts, but the structural complexity increases
Solution Approach 1:
The hinge part connects the clamp moving part to the clamp base part, enabling the clamp moving part to move between opened and closed positions. This dynamic design provides retention flexibility for accommodating conductors of different sizes and types, while the simple hinge mechanism adds minimal structural complexity compared to more complex adjustable or removable retention systems.
Data Source
AI summary
A clamp includes a clamp base part having a first step, a hinge part that is formed on a thinned portion connected continuously to the clamp base part, a clamp moving part having a second step, and a plurality of retention parts formed in a state that the clamp moving part is engaged with the clamp base part. The clamp base part is provided on a structure in which a cable and/or an electric wire is routed and formed such that the cable and/or the electric wire is placed thereon. One end of the clamp moving part is connected continuously to the hinge part, the other end of the clamp moving part is engaged with the clamp base part, and the cable and/or the electric wire is covered from the one end to a middle portion of the clamp moving part.