Sliding Busbar Holder Lock Structure for Stable Assembly
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Solution Overview
Problem
Conventional busbar holders face challenges in enhancing assemblability to the busbar, particularly in terms of ease of assembly and stability during the manufacturing process.
Innovation Solution
A busbar holder design featuring a base with a groove for slidably supporting a cover, a cover with through holes, and a lock member with protrusions that clamp the busbar between the base and the cover, utilizing locking portions to secure the assembly in the stacking direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional busbar holder structure is used, then the basic holding function is provided, but the assemblability to the busbar is insufficient
Solution Approach 1:
The busbar holder is divided into three main segments: a base, a cover, and a lock member. This segmentation allows each component to be manufactured independently and assembled in a straightforward sequence, improving assemblability without requiring complex integrated structures. The base provides the foundation, the cover protects the insertion space, and the lock member secures the busbar, with each segment having a specific function that simplifies the overall assembly process.
Solution Approach 2:
The lock member is designed with a protrusion that preliminarily engages with the busbar during the assembly process. This preliminary action guides the busbar into the correct position within the insertion space before final locking occurs. The groove on the base and corresponding structure on the cover are pre-configured to facilitate this preliminary engagement, making the assembly process more intuitive and easier to perform correctly.
2Ease of manufacture
If the busbar holder structure is simplified, then manufacturing is easier, but stability during assembly is reduced
Solution Approach 1:
By segmenting the holder into base, cover, and lock member, each component can be manufactured using simple, standard processes without requiring complex multi-step manufacturing. The segmented design allows for easier quality control and manufacturing tolerances while maintaining overall assembly stability through the designed interfaces between segments.
Solution Approach 2:
The lock member combines multiple functions into a single component: it clamps the busbar using its protrusion, locks the cover to the base, and provides structural support. This merging of functions maintains assembly stability without requiring multiple separate components, thus preserving ease of manufacture. The integrated lock member eliminates the need for additional fasteners or securing mechanisms.
3Reliability
If the lock member design is added, then the busbar clamping and fixation are improved, but the device complexity increases
Solution Approach 1:
The lock member is designed as a multi-functional component that simultaneously clamps the busbar, secures the cover to the base, and provides structural support. This universality means that one additional component performs multiple critical functions, improving busbar fixation reliability without proportionally increasing device complexity. The single lock member replaces what would otherwise require multiple separate fastening and clamping mechanisms.
Solution Approach 2:
The lock member features a self-clamping mechanism where the protrusion automatically engages with the busbar and secures it in place during the assembly process. The design allows the lock member to serve itself in positioning and clamping the busbar without requiring external tools or additional adjustment mechanisms, thereby improving fixation reliability while minimizing the increase in device complexity.
Data Source
AI summary
A busbar holder includes a base, a cover, and a lock member. The base includes a groove that slidably supports the cover in an axial direction, and a pair of locking portions provided at both ends in a width direction. The cover includes a through hole penetrating the cover in a stacking direction. The lock member includes: a protrusion protruding in the stacking direction, and provided to be inserted into the through hole of the cover to clamp a busbar between the protrusion and the base; and a pair of locked portions being provided at both ends in the width direction and provided to be locked to the pair of locking portions of the base in a state where the protrusion is inserted into the through hole.