Wiring Harness Connector Layout for Faster Terminal Identification
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Solution Overview
Problem
Conventional connectors for wiring harnesses in vehicles face challenges in assembling workability due to the complexity of identifying and connecting terminals with different shapes and intervals, leading to increased time and effort during assembly.
Innovation Solution
The connector design incorporates identifying portions on the terminals, which are mutually different in shape based on their intervals, allowing for easier identification and connection, even when held by the housing, and includes an interlock connector for proper positioning verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If terminals are arranged with different intervals for wire connecting portions and terminal connecting portions, then terminal identification becomes more complex, but assembling workability deteriorates
Solution Approach 1:
The terminal is divided into distinct functional portions: wire connecting portions, intermediate portions, and terminal connecting portions. Each portion serves a specific function and can be independently identified. The intermediate portions are further segmented into different shapes (first, second, third intermediate portions) to provide visual identification cues for different terminals, making assembly easier despite the complex interval arrangement.
Solution Approach 2:
Different portions of the terminal structure have different properties: the wire connecting portions have uniform intervals for standardized wire attachment, while the terminal connecting portions have different intervals to match specific mating terminals. The intermediate portions have distinct shapes (different local qualities) that provide identification without affecting the electrical connection function.
2Ease of operation
If terminals have different shapes for identification, then assembling workability improves, but device complexity increases
Solution Approach 1:
The intermediate portions of different terminals are designed with asymmetric shapes - first intermediate portions, second intermediate portions, and third intermediate portions with distinct geometries. This asymmetry provides clear visual and tactile identification for assembly workers, allowing them to quickly match terminals to their correct positions without confusion, thereby improving assembling workability.
Solution Approach 2:
Instead of making the wire connecting portions different shapes for identification (which would complicate the electrical connection function), the invention inverts the approach by making the intermediate portions different shapes. This keeps the critical wire connecting portions simple and uniform, while providing identification features in the intermediate sections that do not affect electrical functionality.
Data Source
AI summary
A connector is provided with three or more terminals to be respectively connected to wires, and a housing for holding the three or more terminals. The three or more terminals are arranged along a first direction. Each of the terminals includes a wire connecting portion to be connected to the wire, a terminal connecting portion to be connected to a mating terminal and an intermediate portion provided between the wire connecting portion and the terminal connecting portion. Three or more of the terminal connecting portions are arranged at intervals along the first direction. Three or more of the wire connecting portions are arranged at intervals along the first direction. The intervals and the intervals are different from each other. Three or more of the intermediate portions are formed to have mutually different shapes according to differences between the intervals and the intervals.