Connector Shell Welding Without Fixing Jig
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Solution Overview
Problem
The existing connector manufacturing process requires a maintenance mechanism, such as a fixing jig, to weld the shell and additional members, increasing manufacturing costs and complexity.
Innovation Solution
A connector design featuring a housing with press-fit holes and a shell with connection portions that allow for press-fitting and welding without the need for a maintenance mechanism, using a cylindrical portion that covers the body portion of the housing and additional members with press-fit and connection portions that can be welded in place without external assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a maintenance mechanism such as a fixing jig is used to weld the shell and additional members, then the welding can be performed with proper positioning, but the manufacturing cost increases
Solution Approach 1:
The connector structure enables self-positioning during assembly. The shell and additional members are designed with complementary geometric features that automatically align and maintain proper positioning during welding without requiring external fixing jigs or maintenance mechanisms, thereby eliminating the associated manufacturing costs while preserving welding precision
Solution Approach 2:
The design incorporates pre-formed connection portions and positioning features on both the shell and additional members that are prepared in advance during component manufacturing. These pre-prepared features ensure that when assembly occurs, the components naturally fit together in the correct position, eliminating the need for complex positioning mechanisms during the welding process
2Manufacturing precision
If a maintenance mechanism such as a fixing jig is used to weld the shell and additional members, then the welding can be performed with proper positioning, but the device complexity increases
Solution Approach 1:
The connector components are designed to self-position and self-align during assembly through integrated geometric features. The shell and additional members automatically maintain proper relative positioning during welding without requiring external fixing jigs or maintenance mechanisms, thereby eliminating the complexity of such mechanisms while preserving welding precision
Solution Approach 2:
The design merges the positioning function and the structural function into a single integrated component design. The connection portions and positioning features are combined directly into the shell and additional members themselves, eliminating the need for separate positioning mechanisms or maintenance devices, thus reducing overall device complexity
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
Enables the attachment and welding of shell and additional members without a maintenance mechanism, reducing manufacturing costs and simplifying the process while maintaining a secure attachment.
Implementation Method 1
The press-fit portion of each of the additional members is connected to the main portion, extends in a direction intersecting with the front-rear direction and is press-fit in the corresponding press-fit hole of the housing
Implementation Method 2
The connection portion of each of the additional members extends from the main portion along the front-rear direction and is welded to the corresponding connected portion of the shell
Data Source
AI summary
A connector is mateable with an object along a front-rear direction. The connector comprises a housing, a shell and an additional member. The housing has a base portion and a body portion. The body portion extends forward from the base portion along the front-rear direction. The shell has a cylindrical portion which covers the body portion of the housing in a plane perpendicular to the front-rear direction. The cylindrical portion has a connected portion. The additional member is press-fit in the base portion of the housing and has a main portion and a connection portion. The connection portion of the additional member extends from the main portion along the front-rear direction and is welded to the connected portion of the shell. The body portion of the housing and the connection portion sandwich the connected portion in a perpendicular direction perpendicular to the front-rear direction.