Electric Connecting Structure With Molded Cable Holder
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Solution Overview
Problem
The existing electric connecting structures for electric motors in fan units of automobiles are complex to automate, requiring precise positioning of cables and terminals, which leads to unstable connections and increased time and costs for wiring operations.
Innovation Solution
An electric connecting structure with a cable holder molded onto the cables, integrated into an outer casing, and an electronic component connected between the cables, simplifying the wiring process by eliminating the need for precise cable and terminal positioning, using injection molding for the cable holder and resistance welding for connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are respectively positioned and welded to metal terminals, then stable electrical connection is achieved, but the wiring operation becomes complex and difficult to automate
Solution Approach 1:
The cable holder integrates multiple functions: it holds multiple cables simultaneously, provides positioning features for automated assembly, and incorporates welding guides for precise terminal alignment. This merging of functions reduces wiring complexity while maintaining connection stability.
Solution Approach 2:
The cable holder acts as an intermediary component between the cables and the outer casing assembly. It pre-positions cables and provides standardized interfaces for automated welding to terminals, simplifying the overall wiring process while ensuring reliable connections.
2Reliability
If precise positioning of cables and terminals is performed, then stable connection is achieved, but time and costs for wiring operations increase
Solution Approach 1:
The cable holder is pre-formed with positioning features, cable clamps, and welding guides before assembly. This preliminary preparation eliminates the need for time-consuming precise positioning during final assembly, maintaining connection stability while improving wiring efficiency.
Solution Approach 2:
The cable holder transforms the positioning parameters from requiring high precision manual adjustment to fixed geometric relationships defined by the molded structure. This parameter transformation enables automated assembly while maintaining stable connections.
3Reliability
If traditional wiring method with separate positioning is used, then connection stability can be achieved, but automation of wiring operation becomes difficult
Solution Approach 1:
The cable holder's molded structure automatically performs positioning and alignment functions through its integrated features. The cables are self-positioned within the holder's clamps, and the welding guides automatically align with terminals, enabling automated wiring operations while maintaining stable connections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the wiring operations, reduces time and costs, and ensures stable connections by holding the cables securely and allowing for easy assembly without the need for precise positioning, enhancing the reliability of the electric connecting structure.
Implementation Method 1
forming at least one cable holder integral with the at least two cables by injection molding
Implementation Method 2
connecting the ends of the at least two cables and corresponding electrical connection terminals
Data Source
AI summary
An electric connecting structure is provided, which includes an outer casing, at least two electrical connection terminals, at least two cables, and an electronic component. At least part of each electrical connection terminal is fixed in the outer casing. Each of the at least two cables has an end connected to the corresponding electrical connection terminal. The electric connection structure further includes at least one cable holder molded onto the at least two cables and mounted in the outer casing. The electronic component is connected between the ends of the at least two cables. The electric connection structure can simplify the wiring operations and consequently reduce the time and costs required for the wiring operations.