Electrical Connection Box Cover Locking via Cable Tension
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical connection boxes have a design flaw where the cover can inadvertently open or close regardless of the connection state between the terminal and the connector, potentially leading to unsafe or inefficient power supply.
Innovation Solution
Incorporating a restriction portion on the cover that creates tension on the power supply line in the longitudinal direction when the cover moves from the fully closed to fully open position, ensuring the cover cannot move to the fully open position unless the terminal is disconnected from the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cover is made movable to allow access to the bus bar, then the ease of operation is improved, but the reliability deteriorates because the cover may open inadvertently when the terminal is connected
Solution Approach 1:
The restriction portion creates preliminary tension on the power supply line that acts in advance to prevent the cover from opening when the terminal is connected. This counter-force is established before any inadvertent opening can occur, thereby maintaining reliability while preserving operational accessibility when needed.
Solution Approach 2:
The system dynamically adjusts cover movability based on connection state. When the terminal is connected, the restriction portion engages to prevent opening. When disconnected, the cover can be opened freely. This dynamic behavior resolves the contradiction by making the cover movable only when safe to do so.
2Reliability
If the cover is restricted from opening to improve reliability, then the reliability is improved, but the ease of operation worsens because the cover cannot be opened for maintenance or inspection
Solution Approach 1:
The restriction mechanism is not static but dynamically activates only when the terminal is connected. The restriction portion detects the connection state and accordingly enables or disables cover movability. This dynamic approach maintains reliability during operation while preserving ease of operation during maintenance when the terminal is disconnected.
Solution Approach 2:
The system changes the mechanical parameter of cover movability based on the electrical connection state. When connected, the restriction portion engages to prevent movement. When disconnected, the restriction is released and the cover becomes movable again. This parameter change resolves the contradiction by adapting the cover's mechanical behavior to the operational context.
3Ease of operation
If the power supply line is made longer to allow cover movement, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The restriction portion acts as an intermediary mechanism that manages the power supply line tension without requiring excessive line length. Instead of relying on a long power supply line to accommodate cover movement, the restriction portion mediates the tension and allows controlled movement while keeping the line management simple and the device complexity low.
Data Source
AI summary
An electrical connection box is provided with a conductive bus bar, an insulating housing body, a cover, and a power supply line. The cover opens or closes with respect to the housing body at a fully open position and a fully closed position. The housing body has a connector at a position exposed to the outside, with the connector configured so that a terminal provided at a tip of the power supply line is attachable or detachable to or from the connector. A restriction portion, which restricts the power supply line from moving in the longitudinal direction is provided in the cover. In the state where the terminal is connected to the connector, the tension is created on the power supply line in the longitudinal direction by the restriction portion during moving the cover from the fully closed position to the fully open position side.