Cylindrical Terminal Structure for Low-Cost High-Current Plug-In Connections
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Solution Overview
Problem
Existing plug-in terminals for high-current applications, such as charging systems in new energy automobiles, suffer from low material utilization rates, complex machining processes, and high production costs due to the use of copper rods and complex assembly requirements.
Innovation Solution
A cylindrical terminal design with an integrally formed contact, fixing, and connecting sections, manufactured using a cylindrical tube and an extrusion process, featuring axial slots and elastic sheets for improved material utilization, reduced machining complexity, and enhanced electrical and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional terminal body with separate positioning structures is used, then positioning accuracy can be achieved, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent integrates the positioning structure directly into the terminal body by forming a positioning protrusion on the side wall of the terminal body. This merging of functions eliminates the need for separate positioning components while maintaining positioning accuracy, thereby reducing the total number of parts and simplifying assembly.
Solution Approach 2:
The terminal body is designed to serve multiple functions: it provides structural support, electrical connection, and positioning functionality. The positioning protrusion integrated into the terminal body allows the same component to perform both connection and positioning tasks, reducing overall device complexity.
2Adaptability or versatility
If multiple separate components are used for connection, then functional requirements can be met, but assembly steps increase and productivity decreases
Solution Approach 1:
The terminal and connector are designed as integrated units where the terminal body incorporates the positioning structure. This reduces the number of discrete components that need to be assembled, directly decreasing assembly steps and improving productivity while maintaining all necessary functional requirements.
3Shape
If machining operations are performed on curved surfaces, then complex shapes can be achieved, but machining difficulty increases and manufacturing precision decreases
Solution Approach 1:
The patent utilizes a curved outer surface of the terminal body that tapers from the small end to the large end. This curved geometry is designed to facilitate automatic alignment during assembly, where the curvature guides the insertion process and ensures accurate positioning without requiring high-precision machining of complex features.
Solution Approach 2:
The terminal body features an asymmetric tapered shape with different curvature radii at different sections. The first curved surface has a different curvature radius than the second curved surface, creating an asymmetric geometry that guides assembly and simplifies machining by reducing the number of precision-critical features.
4Ease of operation
If automatic insertion is enabled through curved surface design, then ease of operation improves, but machining complexity increases
Solution Approach 1:
The curved outer surface with varying curvature radii is designed to guide automatic insertion by providing a tapered profile that naturally directs the connector into the correct position. While the curved geometry adds some machining complexity, it eliminates the need for complex mechanical guidance mechanisms, overall simplifying the device.
Solution Approach 2:
Instead of adding complex positioning mechanisms to enable automatic insertion, the patent inverts the approach by using the basic tapered curved shape of the terminal body itself as the guiding feature. This simplifies the overall device complexity while maintaining ease of automatic insertion.
Data Source
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AI summary
A cylindrical terminal, including a contact section (10), a fixing section (20) and a connecting section (30). The fixing section (20) includes an extension section (201) and an assembly portion (202) that is injection-molded on the extension section (201). The contact section (10), the extension section (201) and the connecting section (30) are integrally formed as a cylindrical tube. The contact section (10) is provided with at least two axial slots (102), such that a side wall of the extension section (10) is divided into at least two contact elastic sheets (103). The extension section (10) is provided with a depression that is recessed radially inward, such that the contact elastic sheets form arc-shaped structures. The plug-in connection structure includes a plug-in terminal (40) and the cylindrical terminal. A method for machining the cylindrical terminal is also provided.