Crimp Terminal Holder Ribs for Misassembly Detection
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Solution Overview
Problem
Conventional terminal assembly structures face issues with misassembly and poor assembly workability due to the lack of effective detection mechanisms for correct orientation of terminals.
Innovation Solution
A terminal assembly structure featuring a crimp terminal with a crimp portion and a holder having detection ribs and inclined ribs to guide and secure the crimp terminal, ensuring correct orientation and easy detection of misassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional terminal assembly structure without detection mechanism is used, then assembly process is simple, but misassembly cannot be detected and assembly workability is poor
Solution Approach 1:
The detection rib is designed with an asymmetric profile that only permits insertion of the crimp terminal in the correct orientation. The rib's shape creates a geometric constraint that prevents misassembly while maintaining a simple overall structure, resolving the contradiction between reliability and device complexity.
Solution Approach 2:
The detection rib provides self-checking functionality during the assembly process. The structure itself performs the detection function through its geometric design, eliminating the need for external detection devices or complex control systems, thus improving reliability without significantly increasing device complexity.
2Reliability
If detection rib is added to holder, then misassembly detection is improved, but holder complexity increases
Solution Approach 1:
The detection rib employs asymmetric geometry to provide directional guidance and prevent misassembly. This simple yet effective approach achieves high detection accuracy without requiring complex mechanisms, sensors, or control systems, thereby maintaining holder structure simplicity while improving reliability.
Solution Approach 2:
The detection rib is implemented as a simple, inexpensive geometric feature molded into the holder, rather than a separate complex detection device. This approach provides reliable misassembly detection at minimal cost and structural complexity, effectively resolving the contradiction between detection accuracy and holder complexity.
3Adaptability or versatility
If terminal can be assembled in reversed orientation, then assembly flexibility is high, but misassembly risk increases
Solution Approach 1:
The detection rib's asymmetric design creates a unidirectional insertion path that maintains assembly flexibility for correctly oriented terminals while automatically preventing reversed orientation assembly. The geometric constraint ensures that only the correct orientation is mechanically feasible, resolving the contradiction between flexibility and reliability.
Solution Approach 2:
The detection rib is positioned to preemptively block misassembly attempts before they can occur. By placing the detection feature at the insertion interface, the structure prevents reversed orientation assembly from happening, thereby maintaining assembly flexibility for correct orientations while ensuring assembly correctness through preliminary prevention.
Data Source
AI summary
A terminal assembly structure according to an embodiment of the present invention includes: a crimp terminal having a crimp portion configured to crimp and connect a core wire of an electric wire and a fastening portion configured to be fastened by a fastening member; and a holder having a base portion configured to place the crimp terminal when fastening the crimp terminal to the holder. The holder has a detection rib at a position on the base portion to be oppose to the crimp portion of the crimp terminal, the detection rib being configured to interfere with the crimp portion when misassembly of front and back sides of the crimp terminal to the holder occurs.