Circuit Terminal Positioning Structure for Bus Bar Assembly
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Solution Overview
Problem
The conventional circuit structure faces difficulties in positioning the first conductive member, second conductive member, and terminal block due to hidden components and narrow visibility, leading to potential warping and defects, and increasing dimensional accuracy is not practical as it raises manufacturing costs.
Innovation Solution
A circuit structure with an upper case having positioning holes, a bus bar with a through hole, a terminal connected to an electric wire with a bolt, and a lower case that includes a terminal positioning portion and case positioning portions to facilitate easy alignment and positioning without increasing component accuracy, using a nut to sandwich the bus bar and suppress warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the first conductive member and second conductive member are connected by a connection screw and nut in a conventional manner, then the components can be assembled together, but the positioning of components becomes troublesome and difficult to visualize due to hidden components
Solution Approach 1:
A positioning member is introduced as an intermediary component between the first conductive member and second conductive member. This positioning member extends through both components and provides an external reference structure that facilitates visualization and positioning during assembly, while the connection screw and nut maintain their fastening function.
Solution Approach 2:
The positioning member extends in a direction perpendicular to the stacking direction of the conductive members, creating a new dimensional reference. This allows operators to position components by aligning the positioning member from the side rather than trying to align through-holes from the top, improving visibility and positioning accuracy.
2Manufacturing precision
If dimensional accuracy of components is increased to improve positioning accuracy, then component alignment improves, but manufacturing cost increases
Solution Approach 1:
The positioning member serves as a mediator that compensates for dimensional tolerances of the conductive members. By providing an external positioning reference with its own reference surfaces, it allows standard-tolerance components to be assembled with high positioning accuracy without requiring expensive precision manufacturing.
Solution Approach 2:
The positioning member changes the positioning parameter from aligning through-holes (which requires high dimensional accuracy) to aligning reference surfaces of the positioning member (which can be manufactured with standard tolerances). This parameter change enables cost-effective positioning.
Data Source
AI summary
A circuit structure includes: an upper case having positioning holes; bus bars that are provided in an inductor disposed in the upper case and that have through holes; terminals that are connected to electric wires and that have bolts disposed thereon that penetrate the through holes; nuts that sandwich the bus bars between the nuts and the terminals by being screwed onto the bolts; and a lower case that is attached to the upper case. The lower case includes: front walls, left walls, and right walls that project upward from the lower case and position the terminals relative to the lower case by coming into contact with the terminals; and case positioning portions that project upward from the lower case and that are inserted into the positioning holes.