Electrical Module Terminal Positioning for Connector Assembly
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Solution Overview
Problem
The existing on-vehicle electrical units with semiconductor relays face challenges in precise positioning and reliable connection due to press-fit methods, which can lead to bending of connector leads and chipping, making automated assembly difficult and imposing a heavy burden on operators.
Innovation Solution
An electrical module with terminals that are loosely inserted into a connector, utilizing a positioning means to guide the terminals into insertion holes and a fixing means to secure the module in place, ensuring reliable connection without the need for press-fitting, and allowing for heat dissipation through the fixing mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead part is press-fit into the connector hole, then the connector and semiconductor relay module are fixed, but the positioning is difficult and the lead part may be bent
Solution Approach 1:
The invention separates the positioning function from the fixing function by introducing a dedicated positioning protrusion on the connector that engages with a corresponding positioning recess on the semiconductor relay module. This segmentation allows precise positioning to be achieved independently from the press-fit fixing operation, resolving the contradiction between connection reliability and positioning accuracy.
2Productivity
If the semiconductor relay module is press-fit into the connector, then the connection is established, but the connector lead part is bent and chipping occurs
Solution Approach 1:
The invention implements preliminary positioning action before the press-fit operation by engaging the positioning protrusion with the positioning recess. This preliminary action guides the semiconductor relay module into the correct position, ensuring that the lead parts are properly aligned with the connector holes before force is applied, thereby preventing bending and chipping during the press-fit process.
3Productivity
If automated press-fitting is attempted, then productivity increases, but the attaching position complexity makes automation difficult
Solution Approach 1:
The invention enables self-positioning and self-alignment through the positioning protrusion and recess mechanism. The components automatically find their correct relative positions during assembly without requiring complex external positioning devices or sophisticated automated control systems, thereby making automated assembly feasible and simple.
4Ease of operation
If manual press-fitting is used, then positioning can be achieved, but the operator is imposed a heavy burden
Solution Approach 1:
The positioning protrusion and recess mechanism enables self-positioning during assembly, eliminating the need for operators to manually align and position the semiconductor relay module precisely. The mechanical guidance provided by the positioning features performs the positioning function automatically, significantly reducing operator burden while maintaining positioning accuracy.
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 enhances the workability and reliability of the connection process, reducing the risk of damage and operator burden by enabling precise positioning and stable connection of the electrical module to the connector, while allowing for efficient heat release.
Implementation Method 1
heat can be released from the electrical module to the connector through the fixing means
Data Source
AI summary
An electrical module and electrical unit, by which workability of the connection work can be improved without deteriorating reliability of the connection, are provided. The electrical module includes: a receiving member for receiving electronic components; a plurality of terminals extending outside the receiving member on a condition that the terminals are electrically connected to the electronic components, the terminals being loosely inserted in insertion holes of a connector so that the electrical module is connected to the connector; a positioning means for positioning the terminals with regard to the insertion holes of the connector; and a fixing means for fixing the receiving member at a position positioned by the positioning means.