Electrical Connection Box Bus Bar Positioning Ribs
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Solution Overview
Problem
Existing electrical connection box designs face challenges in cost reduction and simplification of die design for positioning bus bars, as current methods are complex and inefficient.
Innovation Solution
The design incorporates a conductive bus bar with first and second ribs in the lower and upper covers, respectively, to facilitate easy positioning without additional members, allowing for assembly and connection to an external connector terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional members such as bus bar pressing covers are used to position bus bars, then positioning accuracy is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The positioning function is merged into the cover structures themselves through the rib projections. The first ribs in the lower cover and second ribs in the upper cover integrate the positioning function that would otherwise require separate pressing covers or additional positioning members, thereby reducing device complexity while maintaining positioning accuracy.
Solution Approach 2:
The covers perform dual functions: structural enclosure and bus bar positioning. The rib projections on the covers automatically position the bus bars during assembly without requiring additional positioning members or complex fixtures, enabling the structure to serve itself for positioning purposes.
2Manufacturing precision
If insert-molding or bus bar division methods are used for positioning, then positioning is achieved, but die simplification and cost reduction are difficult
Solution Approach 1:
The positioning function is segmented into the cover structures through rib projections rather than requiring complex integrated molds. This allows the covers to be manufactured separately with simple rib features, avoiding the need for complex insert-molding dies or specialized bus bar fabrication processes.
Solution Approach 2:
The rib projections provide a simple, cost-effective positioning solution that eliminates the need for expensive specialized fixtures or complex mold designs. The positioning is achieved through basic structural features that are inexpensive to manufacture and implement.
3Stability of the object's composition
If multiple ribs are provided in both covers at different positions, then bus bar positioning stability is improved, but manufacturing complexity increases
Solution Approach 1:
The rib structures in the upper and lower covers are positioned at different locations, creating an asymmetric arrangement that provides stable positioning. This asymmetric positioning prevents the bus bar from shifting during assembly while the rib features themselves remain simple geometric elements that are easy to manufacture.
Data Source
AI summary
An electrical connection box includes a lower cover, an upper cover, a connector front opening, bus bars, four first ribs formed of two pairs opposing each other with the bus bar, formed on the lower cover, interposed therebetween, and four second ribs formed of two pairs opposing each other with the bus bar, formed on the upper cover, interposed therebetween. The first ribs and the second ribs are provided such that a pair of ribs is provided to oppose each other on one side and on another side with the bus bar interposed therebetween in a vertical direction, and a pair of ribs is provided to oppose each other on one side and on another side with the bus bar interposed therebetween in a width direction. When viewed from a direction of assembling, the first ribs and the second ribs are provided at different positions.