Electrical Connection Structure for Error-Proof Unit Insertion
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Solution Overview
Problem
Existing electrical connection structures face challenges in preventing erroneous insertion of power source distribution units into cases and improving the insertion process.
Innovation Solution
The electrical connection structure includes a case with a holding portion and a power source distribution unit that features a bus bar with power source and load connection portions, fuse portions, and a cover. The main body is designed with an approximately twice-rotation symmetrical shape, and includes projections and grooves to guide the power source distribution unit into the correct position, preventing inverse insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the power source distribution unit is designed with a symmetrical shape for ease of manufacture, then manufacturing cost is reduced, but erroneous insertion cannot be prevented
Solution Approach 1:
The patent introduces asymmetric features (projection and groove) into the otherwise symmetrical power source distribution unit. The projection is formed on the main body in a specific direction, and the groove is formed on the cover in a corresponding asymmetric position. This allows the unit to be manufactured efficiently while preventing erroneous insertion, as the projection must align with the groove in the correct orientation.
Solution Approach 2:
The projection and groove are pre-formed during manufacturing as integral features of the power source distribution unit. This preliminary action ensures that when the unit is inserted into the case, the alignment is automatically guided by these pre-formed features, preventing erroneous insertion before the insertion process even begins.
2Ease of operation
If the power source distribution unit is designed with simple insertion structure, then ease of operation is improved, but guidance into correct position is insufficient
Solution Approach 1:
The projection acts as an intermediary element between the power source distribution unit and the case. It mediates the insertion process by physically guiding the unit into the correct position through the groove, ensuring precise positioning while maintaining a simple insertion operation for the user.
Solution Approach 2:
The projection and groove feature adds a dimensional constraint to the insertion process. Instead of relying solely on the insertion force in one dimension, the asymmetric features create a geometric constraint that guides positioning in multiple dimensions simultaneously, improving positioning accuracy without complicating the operation.
Data Source
AI summary
A holding portion in which a power supply distribution unit is inserted and held is formed in a case of an electrical connection structure. Here, the power supply distribution unit includes a main body formed so as to have an approximately twice-rotation symmetrical shape with respect to an imaginary line extending in a first direction. A projection is formed on the main body and/or the holding portion, and a groove into which the projection is inserted, and a restriction wall which interferes with the projection when the power source distribution unit is inversely inserted are formed on the holding portion and/or the main body. Further, a projection side inclined surface capable of guiding the projection into the groove by coming into contact with the restriction wall when the power source distribution unit is inserted in a state of a normal position is formed in the projection.