Bus Bar Mounting Structure With Guide Portion For Terminal Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing bus bar mounting structures face challenges in ensuring accurate and automatic alignment of the electric connection portion with the female-female terminal, leading to interference issues and increased assembly complexity due to potential misalignment and deformation.
Innovation Solution
A bus bar mounting structure featuring a guide portion on a second plate that projects to guide the electric connection portion into a through hole, with an inclined surface to correct the bend, allowing for automatic alignment and secure fitting of the female-female terminal within a recessed portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric connection portion is bent to erect for connection to the female-female terminal, then the connection function is achieved, but the elastic deformation causes misalignment and interference with the terminal
Solution Approach 1:
The guide portion is provided in advance on the second plate to pre-correct the bending angle of the electric connection portion before the female-female terminal is installed. This preliminary action prevents misalignment issues that would otherwise require manual correction during assembly, ensuring the electric connection portion is properly aligned with the terminal from the outset
Solution Approach 2:
The guide portion acts as an intermediary element between the electric connection portion and the female-female terminal. It mediates the alignment process by providing a physical guide that corrects the bending angle, eliminating the need for direct manual adjustment and ensuring precise positioning during automatic assembly
2Manufacturing precision
If manual correction of bends is performed by assembling workers, then the alignment accuracy is improved, but the assembly time and labor cost increase significantly
Solution Approach 1:
The guide portion enables the electric connection portion to self-correct its bending angle during the assembly process. As the bus bar is placed on the second plate, the guide portion automatically guides the electric connection portion into the correct position, eliminating the need for manual intervention and allowing workers to focus on higher-value tasks
Solution Approach 2:
The alignment correction is performed in advance by the guide portion structure rather than during the final assembly step. This preliminary alignment action reduces the skill level and time required for assembly workers, thereby improving overall productivity while maintaining high alignment accuracy
3Manufacturing precision
If the accuracy of bending work is enhanced, then the interference with the terminal is reduced, but various factors such as attaching condition and material properties still cause inclination
Solution Approach 1:
The guide portion serves as a compensating intermediary that absorbs variations in bending accuracy caused by different attaching conditions and material properties. It provides a mechanical reference that ensures proper alignment regardless of the initial bending quality, making the system tolerant to manufacturing variations
Solution Approach 2:
The guide portion structure is designed to accommodate and correct potential misalignments before the female-female terminal is installed. This beforehand cushioning approach ensures that even if bending accuracy varies due to material or attaching condition, the final alignment will be correct, preventing interference with the terminal
Data Source
AI summary
A guide wall and a recessed portion for accommodating therein a female-female terminal are formed in a lower case, and in an intermediate plate, a through hole through which an electric connection portion which is in abutment with the guide wall is formed and a guide portion is provided at a lower edge portion of the through hole so formed so as to protrude therefrom so as to be brought into abutment with the electric connection portion, so that the electric connection portion is guided into the through hole. Thus, by inserting the intermediate plate between the upper case and the lower case so as to be held therebetween, the guide portion automatically corrects the bend of the electric connection portion.