Fuse Unit Asymmetric Bolt Design for Assembly Error Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuse units for vehicles with two batteries face challenges in preventing incorrect assembly due to similar dimensions and directions of connection bolts, leading to potential operational failures.
Innovation Solution
The fuse unit design incorporates alternator and second battery connecting bolts with distinct diameters and orientations, ensuring correct connection by locating them on the upper surface of the unit main body, preventing incorrect assembly and simplifying the connection process in a small working space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connecting bolts for alternator and second battery are made with similar dimensions and directions to simplify manufacturing, then manufacturing complexity is reduced, but assembly correctness cannot be ensured leading to potential operational failures
Solution Approach 1:
The patent applies asymmetry by making the alternator connecting bolt and second battery connecting bolt have different orientations (directions). Specifically, the alternator connecting bolt extends in a first direction while the second battery connecting bolt extends in a second direction that is different from the first direction. This asymmetric design allows assembly workers to easily distinguish between the two bolts and ensures correct assembly, resolving the contradiction between manufacturing simplicity and assembly correctness.
2Reliability
If connecting bolts are made with distinct diameters and orientations to prevent incorrect assembly, then assembly correctness is improved, but device complexity increases
Solution Approach 1:
The patent uses asymmetry in the orientation of connecting bolts to prevent incorrect assembly. The alternator connecting bolt and second battery connecting bolt extend in different directions, creating an asymmetric configuration that is visually and physically distinct. This approach improves assembly correctness without significantly increasing device complexity, as the bolts remain structurally simple but differ in their spatial arrangement.
Solution Approach 2:
The patent applies local quality by differentiating specific properties (orientation and direction) of local components (connecting bolts) while keeping the overall structure simple. Each bolt has a specific orientation tailored to its connection point, allowing correct assembly through localized differentiation rather than complex global design.
3Ease of operation
If all connecting bolts extend in the same direction to simplify assembly process, then ease of operation is improved, but ability to distinguish between different connection points is reduced
Solution Approach 1:
The patent resolves this contradiction by introducing asymmetry in the orientation of connecting bolts. While this requires slightly more attention during assembly compared to identical bolts, the clear directional differences (first direction vs. second direction) make it extremely easy to distinguish between connection points. This maintains ease of operation while significantly improving connection differentiation.
Data Source
AI summary
An alternator connecting bolt of an alternator connecting end has a diameter different from that of a second battery connecting bolt of a second battery connecting end.