Wiring Connector Housing With Interference Tabs for Relay Alignment
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Solution Overview
Problem
Current air conditioning systems face errors in wire connections due to the similarity in male quick disconnect terminals on multi-pole relays, leading to potential malfunctions during manufacturing, assembly, and troubleshooting.
Innovation Solution
A wiring connector housing with interference tabs that contact isolation ridges on electrical relays, preventing improper registration and ensuring correct alignment with corresponding terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If all terminals on the multi-pole relay are made with the same male quick disconnect type, then the relay structure is simplified and easier to manufacture, but the possibility of incorrect wire connections increases significantly
Solution Approach 1:
The patent introduces interference tabs with asymmetric shapes (different lengths and positions) that correspond to isolation ridges on the relay. This asymmetric design allows only one correct orientation for the wiring connector housing to be mounted, preventing incorrect connections while maintaining simple male quick disconnect terminals. The interference tabs create a mechanical key-lock system where mismatched orientations are physically blocked.
2Device complexity
If the wiring connector housing is designed without interference tabs, then the device complexity is reduced, but the ability to prevent improper registration with terminals is lost
Solution Approach 1:
The interference tabs are pre-configured on the wiring connector housing to prevent improper registration before any electrical connection can be made. The tabs extend beyond the housing body and are positioned to contact isolation ridges on the relay, creating a preliminary mechanical barrier that blocks incorrect orientations. This anti-action is built into the structure itself, requiring no active control or additional components.
3Reliability
If interference tabs are added to the wiring connector housing, then incorrect connections are prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The interference tabs are formed as integral parts of the wiring connector housing during the initial molding process. The tabs are pre-positioned and pre-shaped with the correct dimensions and orientations, eliminating the need for separate manufacturing steps or assembly operations. This preliminary action during manufacturing ensures the anti-corrective function is built-in without adding significant complexity to the production process.
Data Source
AI summary
A wiring connector housing including a housing body having first and second ends and at least one interference tab extending outwardly from the second end is provided. The wiring connector housing further comprises spaced apart channels located through the housing body extending from the first end to the second end with the first end of the channels each configured to receive a quick connector therein. Each of the second ends of the spaced apart channels being located to register with and receive corresponding quick connect terminals therein. The at least one interference tab is configured to contact an isolation ridge of an electrical relay and thereby prevent the second ends of the spaced apart channels from being improperly registered with the corresponding quick connect terminals.