Device Connector Guide Member for Flexible Wire Positioning
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Solution Overview
Problem
Conventional devices for connecting motors and inverters in electric vehicles face issues with positional displacement and deformation of flexible braided wires, leading to interference and difficulties in connecting terminals.
Innovation Solution
A device connector with a terminal metal fitting featuring a flexible conductive member linked by a guide member, which reduces unnecessary deformation and displacement by fitting the connecting end into an insertion hole, and includes a lock plate for secure assembly and simplified operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible braided wire is interposed in the inverter-side terminal to absorb positional displacement, then the terminal can accommodate misalignment between the inverter-side housing and terminal base, but the braided wire may interfere with other members and undergo unnecessary deformation
Solution Approach 1:
A guide member is introduced as an intermediary component between the inverter-side housing and the terminal base. This guide member provides a defined path for the flexible braided wire, guiding it through an insertion hole to reach the terminal base. By serving as a mediator, the guide member prevents the braided wire from interfering with other members while maintaining its ability to absorb positional displacement through controlled flexibility.
Solution Approach 2:
The functional capability of positional displacement absorption is extracted from the flexible braided wire itself and transferred to a dedicated guide member structure. The guide member is specifically designed with an insertion hole that allows the braided wire to pass through while maintaining a defined trajectory. This separation of functions allows the braided wire to focus on electrical connection while the guide member manages the mechanical guidance and displacement absorption.
2Device complexity
If the inverter-side housing is directly connected to the motor case, then the assembly structure is simplified, but the terminal metal fitting may undergo deformation and displacement due to positional misalignment
Solution Approach 1:
The guide member acts as a mediator between the inverter-side housing and the terminal base, providing a precise alignment path through its insertion hole. This intermediary structure ensures that the terminal metal fitting maintains proper positioning during assembly, preventing deformation and displacement even when direct connection between housing and case is used for simplicity.
3Ease of operation
If the braided wire is bent and led rearward from the inverter-side housing, then connection to the inverter output terminal is enabled, but the posture of the braided wire may be displaced making connection difficult
Solution Approach 1:
The guide member with its insertion hole serves as a mediator that defines the routing path for the braided wire. Instead of allowing the wire to be bent and led rearward in an uncontrolled manner, the guide member provides a structured pathway that maintains proper wire posture and orientation, making the connection operation easier and more reliable.
Data Source
AI summary
A device connector includes: a terminal metal fitting 70 including a first connecting portion 71, a second connecting portion 72, and a flexible conductive member 73 linking the connecting portions 71, 72; a housing 80 having a cavity 81 for accommodating the first connecting portion 71; and a guide member 90 attached to a rear surface of the housing 80, and having an insertion hole 93 opened concentrically with the cavity 81, the insertion hole 93 corresponding to a connecting end of the flexible conductive member 73 of the terminal metal fitting 70 to be connected to the first connecting portion 71. The flexible conductive member 73 has a connecting end to be connected to the second connecting portion 72 extending outside the guide member 90 through the insertion hole 93.