Busbar Connector Opening Structure for Flexible Manufacturing
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Solution Overview
Problem
Existing manufacturing facilities for connector blocks with busbars are inflexible, requiring significant changes to produce different types, leading to increased costs.
Innovation Solution
A connector design featuring a separate cover member that forms openings with the connector body, allowing for various types to be manufactured without large-scale facility changes, using a supporting mechanism, guiding portions, and lock mechanism to secure the cover member in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If connector blocks are insert-molded with busbars for each shape of fitting opening, then manufacturing precision and reliability are improved, but device complexity and manufacturing cost increase due to requiring different facilities for different types
Solution Approach 1:
The connector block is divided into two separate components: the main body and the cover member. The cover member is formed separately and then attached to the connector body to form the opening. This segmentation allows the main connector body to remain standardized while only the cover member needs to be varied for different opening shapes, enabling production using the same manufacturing facility.
Solution Approach 2:
A single standardized connector body design can be used for multiple types of connectors by combining it with different cover members that have various opening shapes. This universality allows one manufacturing facility to produce multiple connector types without requiring large-scale changes to the facility.
2Ease of manufacture
If different types of connector blocks are manufactured using existing facilities, then manufacturing cost is reduced, but manufacturing precision and reliability deteriorate due to facility limitations
Solution Approach 1:
By separating the connector block into a standardized body and a separately formed cover member, the invention enables production using existing facilities for the cover member while maintaining high precision through specialized cover member manufacturing processes.
3Adaptability or versatility
If the cover member is formed separately and mounted on the connector body, then adaptability for different opening shapes is improved, but device complexity increases due to additional components
Solution Approach 1:
The cover member is attached to the connector body through a snap-fit mechanism where protrusions on the cover member engage with recesses in the connector body. This merging creates a unified structure that provides multiple opening shapes while maintaining structural integrity and avoiding excessive complexity.
4Reliability
If the cover member is securely attached to the connector body, then reliability is improved, but device complexity increases due to attachment mechanisms
Solution Approach 1:
The cover member features protrusions that automatically engage with recesses in the connector body during assembly, creating a self-locking snap-fit attachment. This self-service mechanism ensures reliable attachment without requiring additional fasteners or complex assembly steps.
Data Source
AI summary
A connector 1 includes a connector body 2 mounted with a busbar 6 to be electrically connected to a terminal of a mating connector 4. The connector 1 includes an opening forming portion 12 integrally provided to the connector body 2 and a cover member 3 to be mounted on the connector body 2. The opening forming portion 12 forms a part of an opening 5, in which a tip portion 8 of the busbar 6 is arranged and which serves as a fitting location of the mating connector 4, in the connector body 2. The cover member 3 is formed separately from the connector body 2 and forms the opening 5 together with the opening forming portion 12 when being mounted on the connector body 2.