Electrical Connection Box Layout With Integrated Relay Mounting
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Solution Overview
Problem
Conventional electrical connection boxes have a high number of components, which increases manufacturing time and cost.
Innovation Solution
The electrical connection box is designed with a housing composed of a lower and upper cover, incorporating a busbar and relays connected via bolts, and a second relay with a tab terminal passing through an opening in the upper cover, eliminating the need for a separate base plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional electrical connection box structure with base plate, lower cover, and upper cover is used, then the housing structure is complete and functional, but the number of components increases
Solution Approach 1:
The base plate is merged with the lower cover into a single integrated component. The lower cover itself forms the mounting surface for the busbar and relays, eliminating the need for a separate base plate structure while maintaining all necessary mounting functions
Solution Approach 2:
The lower cover serves multiple functions simultaneously: it provides the housing enclosure, the mounting surface for busbar and relays, and the structural base for the entire assembly, replacing what would traditionally require separate base plate and cover components
2Productivity
If more components are used in the electrical connection box, then the structural completeness and functionality are maintained, but the manufacturing time increases
Solution Approach 1:
By combining the base plate and lower cover into one piece, the number of parts to be manufactured, shipped, and assembled is reduced, directly decreasing manufacturing time and production complexity
3Ease of manufacture
If more components are used in the electrical connection box, then the structural completeness and functionality are maintained, but the production cost increases
Solution Approach 1:
Reducing the component count from three separate parts (base plate, lower cover, upper cover) to two integrated parts (combined lower cover-base plate, and upper cover) decreases material costs, manufacturing costs, and assembly costs
Data Source
AI summary
An electrical connection box includes a housing configured by a lower cover and an upper cover, a busbar, a first relay, and a second relay. The lower cover includes a busbar placed portion where the busbar is placed on one side in a stacking direction and a first relay mounted portion where the first relay is mounted on the one side in the stacking direction. The upper cover includes a second relay mounted portion that covers the one side in the stacking direction of the busbar placed on the busbar placed portion, that mounts the second relay on the one side in the stacking direction, and that is provided with an opening, and a cover portion covering the first relay and a bolt.