Electrical adapter
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Solution Overview
Problem
Conventional control units for electric heating devices require complex assembly processes due to the positioning and fastening of components, which hinders automation and increases the risk of errors.
Innovation Solution
An electrical adapter with a support structure that includes electrical connections, a screw connection aperture, and positioning aids, allowing for precise and easy assembly of control unit components, enhancing automation and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional control units use separate components for electronics housing, control electronics, and adapter, then electrical connection functionality is achieved, but assembly process complexity increases and automation becomes difficult
Solution Approach 1:
The patent combines the adapter and electronics housing into a single integrated component. The adapter serves dual functions: providing electrical connections and serving as the housing structure. This merging eliminates the need for separate positioning and fastening operations between distinct components, enabling automated assembly while maintaining all necessary electrical connection functionalities.
Solution Approach 2:
The integrated adapter-housing component performs multiple functions simultaneously: it provides mechanical protection for control electronics, establishes electrical connections via integrated terminals, and serves as the mounting structure. This multi-functionality reduces the number of assembly steps and components required, directly improving automatability while maintaining device functionality.
2Productivity
If conventional control units use complex positioning and fastening methods for components, then secure assembly is achieved, but assembly time and error risk increase
Solution Approach 1:
By integrating the adapter and housing, the patent eliminates multiple positioning and fastening steps that would be required for separate components. The single integrated structure requires only one assembly operation, significantly reducing assembly time and eliminating positioning errors that could occur with multiple separate component alignments.
3Reliability
If conventional control units use multiple separate components, then electrical connection reliability is achieved, but assembly error risk increases
Solution Approach 1:
The integrated adapter-housing design ensures that electrical connections are built into the structure itself rather than requiring separate connection components. This eliminates positioning errors between separate components and ensures consistent, reliable electrical connections through precision-molded integrated terminals, maintaining connection reliability while improving assembly precision.
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to an electrical adapter (1) for electrically connecting a control unit (2) of a heating device to an electrical energy source (E) and to an electrical signals source, comprising a support (3) made of an electrically insulating plastic material in which an electrical supply line (4) and an electrical signal line (7) are embedded, these lines (4, 7) at one of their ends merging into a supply or signal connection (5, 8) and at their other end into a supply or signal interface (6, 9), wherein an aperture (10) is present on the support (3) for forming a screw connection which the adapter (1) can be connected to an electronics housing (11) of the control unit (2) with, the support (3) comprising at least one positioning aid (12) for positioning the adapter (1) relative to the control electronics and/or the electronics housing (11), the positioning aid (12) being arranged between the two interfaces (6, 9) and the aperture (10).