Crimp Terminal Holder Structure 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 potential for terminals to be assembled in reversed orientations.
Innovation Solution
The terminal assembly structure incorporates a terminal placing base with detection ribs and inclined ribs to guide the crimp terminal, ensuring correct alignment and preventing misassembly, while the fastening portion of the crimp terminal features an oval hole for the bolt, facilitating easy and secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional terminal assembly structure is used, then assembly process is simple, but misassembly cannot be detected and assembly workability is poor
Solution Approach 1:
The patent applies asymmetry by providing detection ribs that protrude from the insulator at positions asymmetric to the crimp terminal's crimping pieces. When the terminal is correctly assembled, the crimping pieces fit between the detection ribs without interference. However, if the terminal is reversed or misassembled, the asymmetric detection ribs contact the crimping pieces, preventing incorrect assembly and enabling easy detection of misassembly through the protruding ribs.
2Reliability
If detection ribs are added to prevent misassembly, then misassembly detection improves, but assembly workability may deteriorate
Solution Approach 1:
The detection ribs are pre-positioned on the insulator before assembly occurs. This preliminary arrangement ensures that when the crimp terminal is inserted, the crimping pieces automatically engage with the detection ribs if misassembled, providing immediate feedback. The preliminary positioning of detection ribs eliminates the need for complex detection mechanisms during assembly, maintaining ease of operation while ensuring reliability.
3Ease of operation
If terminal orientation is not controlled, then assembly process is flexible, but misassembly occurs
Solution Approach 1:
The asymmetric arrangement of detection ribs relative to the insulator geometry, combined with the symmetric crimping pieces on the terminal, creates an orientation-dependent assembly system. The terminal can only be correctly inserted when its crimping pieces align with the spaces between detection ribs. This asymmetric design maintains assembly flexibility for correct orientations while automatically preventing misassembly through physical interference when oriented incorrectly.
Data Source
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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.