Connector Lance Segmentation for Half-Insertion Detection
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Solution Overview
Problem
In connectors with a lance integrally formed in the terminal accommodating chamber, insufficient insertion of the terminal fitting can result in incomplete engagement and unreliable detection of half-insertion states, leading to inadequate engaging force and potential spacer fitting issues.
Innovation Solution
The connector design includes a lance with a sliding part, an abutting part, and an engaging part, featuring a chamfered surface that ensures complete engagement by generating a distinct sound upon return to the original state, preventing half-insertion and ensuring a reliable detection mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the terminal fitting is inserted by a sufficient amount to ensure complete engagement with the lance, then the engaging force is adequate, but the detection of half-insertion state becomes difficult
Solution Approach 1:
The lance is divided into functionally distinct segments: a sliding part that contacts the terminal fitting during insertion, an abutting part that provides a stopping position, and an engaging part that secures the terminal fitting. This segmentation allows the system to provide both adequate engaging force through the engaging part and reliable half-insertion detection through the abutting part's distinct stopping position.
Solution Approach 2:
The abutting part is positioned to contact the terminal fitting before the engaging part engages, creating a preliminary stopping position. This preliminary action allows the system to detect half-insertion states (when the terminal fitting stops at the abutting part) before complete engagement occurs, enabling early detection and prevention of improper assembly.
2Reliability
If the lance is designed to return completely to its original state for proper engagement, then the engaging force is ensured, but half-insertion may occur when insertion is slightly insufficient
Solution Approach 1:
The abutting part acts as a cushioning element that stops the terminal fitting before complete engagement. This beforehand cushioning prevents the lance from being forced into an incomplete return state, ensuring that even with slight variations in insertion amount, the lance can reliably return to its original engaged state when properly inserted, while still providing a detectable stopping position for half-insertion cases.
Solution Approach 2:
The abutting part serves as an intermediary element between the sliding part and the engaging part. It mediates the insertion process by providing an intermediate stopping position that allows detection of insufficient insertion, while the engaging part ensures complete engagement when the terminal fitting is properly inserted. This intermediary structure bridges the gap between detection and secure engagement functions.
3Strength
If the terminal engaging part is located at the end position of the lance, then the engagement is maximized, but the restoring process and engagement start simultaneously causing detection issues
Solution Approach 1:
The lance is segmented into distinct functional zones: the sliding part at the end for initial contact and stopping, the abutting part for providing a defined stopping position, and the engaging part positioned to maximize engagement strength. This spatial segmentation allows the terminal engaging part to be optimally positioned for strength while the abutting part provides a separate detection point that operates independently during the insertion process.
Solution Approach 2:
The abutting part provides a preliminary stopping action before the engaging part engages. When the terminal fitting is inserted, it first contacts the abutting part which stops its movement, allowing detection of the half-insertion state. Only when sufficient insertion force is applied does the terminal fitting overcome the abutting part and engage with the engaging part, separating the detection phase from the engagement phase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively prevents half-insertion and ensures a strong engaging force, improving the reliability of detecting half-insertion states by utilizing the sound generated during engagement.
Implementation Method 1
a lance having flexibility is integrally formed in the terminal accommodating chamber. When the terminal fitting is inserted into the terminal accommodating chamber by a prescribed amount while bending the lance, the bent lance is restored to an original state and is engaged with the terminal fitting.
Data Source
AI summary
A connector includes a connector housing having a terminal accommodating chamber, and a terminal fitting, and a lance. The terminal fitting includes: a lance sliding part formed in a shape of a flat face parallel to an inserting direction of the terminal fitting; a lance abutting part formed in a shape of a flat face which is different in level from the lance sliding part by a stepped part; and a lance engaging part. The lance includes a terminal engaging part which engages the lance engaging part; a terminal slide part which slides on the lance sliding part during an inserting process of the terminal fitting into the terminal accommodating chamber; and a chamfered part and a terminal abutting part which are located between the terminal engaging part and the terminal slide part.