Electrical Connector Assembly With Terminal Position Assurance
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Solution Overview
Problem
Existing electrical connectors face difficulties in automatic assembly and are prone to cable deformation during the assembly process, especially with small wire diameter cables, leading to high production costs and low efficiency.
Innovation Solution
The electrical connector incorporates a terminal position assurance member with a terminal fixing portion that securely connects the terminal to the housing, allowing synchronous mounting with the cable, thereby simplifying the assembly process and reducing cable deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal and cable are inserted into the insertion slot during assembly, then the electrical connector is assembled, but the cable is likely to be deformed and the insertion is difficult
Solution Approach 1:
The terminal position assurance member is pre-installed on the terminal before assembly, establishing the correct position and orientation of the terminal in advance. This preliminary positioning action prevents cable deformation during the subsequent assembly process by ensuring the terminal is already correctly oriented when inserted into the housing.
Solution Approach 2:
The terminal position assurance member acts as an intermediary component between the terminal and the housing. It provides a standardized interface that guides the terminal into the correct position during assembly, making the insertion process easier and reducing cable deformation risks for small wire diameter cables.
2Productivity
If manual assembly is used for inserting terminal and cable, then assembly can be performed, but working efficiency is affected and operation is complicated
Solution Approach 1:
The terminal position assurance member is designed to automatically guide the terminal and cable into the correct position during assembly. The component's structure includes positioning features that self-align with the housing, eliminating the need for complex manual positioning operations and enabling easier automated assembly.
Solution Approach 2:
The assembly system is segmented into distinct components: the terminal position assurance member attached to the terminal, and the housing with insertion slots. This segmentation allows each component to be independently prepared and then easily assembled together, improving workflow efficiency and reducing operational complexity.
3Extent of automation
If terminal is inserted without position assurance member, then assembly is simpler, but automatic assembly cannot be realized
Solution Approach 1:
The terminal position assurance member is pre-attached to the terminal with positioning features that protrude outward. This preliminary preparation enables automated assembly equipment to easily identify and position the terminal correctly during automated insertion into the housing,实现ing automatic assembly capability.
Solution Approach 2:
The terminal position assurance member introduces specific geometric parameters (protruding positioning features with defined shapes and positions) that transform the terminal from a simple component into one that can be automatically positioned. These parameter changes enable automated detection and positioning systems to function effectively.
Data Source
AI summary
An electrical connector includes a terminal having an end connecting to a cable, a terminal position assurance member having a terminal fixing portion fixedly connecting to the terminal, and a housing. The terminal is mounted to the housing together with the terminal position assurance member.