Fusible Link Unit Half-Fitting Prevention
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Solution Overview
Problem
The existing fusible link units are prone to a half-fitting state where the transparent resin cover is easily dislodged by a light shock due to incomplete engagement, leading to increased production costs when detection units like height sensors are used to address this issue.
Innovation Solution
Incorporating half-fitting prevention projections with cover guiding portions on the exposing window portion to ensure complete locking and prevent half-fitting without the need for additional detection units, allowing users to detect and correct improper fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If locking projections and locking portions are used to lock the resin cover on the exposing window portion, then the resin cover can be locked, but a half-fitting state may occur where the resin cover is easily dislodged by light shock
Solution Approach 1:
The resin cover itself serves as the detection mechanism through its transparent property. When properly locked, the cover is invisible against the transparent exposing window portion. When improperly locked (half-fitting state), the cover becomes visible and can be easily dislodged. This eliminates the need for separate detection units while maintaining reliability.
Solution Approach 2:
The patent utilizes the optical property of transparency/visibility as a detection mechanism. The resin cover's visibility change based on its fitting state provides visual feedback to users without requiring additional sensors or detection devices.
2Manufacturing precision
If detection units like height sensors are used to detect half-fitting state, then improper fitting can be detected, but production costs increase
Solution Approach 1:
The resin cover's transparent property and visibility change serve as the detection mechanism. When properly fitted, the cover blends with the transparent exposing window portion and is invisible. When improperly fitted, it becomes visible, providing automatic detection without additional sensors or complex manufacturing processes.
Solution Approach 2:
The patent uses the existing transparent resin cover material itself as the detection element rather than adding expensive detection units. The cover's optical properties provide the detection function at no additional material cost.
3Productivity
If the resin cover is locked only at one longitudinal side portion (half-fitting state), then assembly may be faster, but the cover is easily dislodged by light shock
Solution Approach 1:
The resin cover's visibility provides immediate feedback on assembly quality. When assembled quickly in a half-fitting state, the cover remains visible and can be easily dislodged. When properly assembled, the cover becomes invisible and locked securely, allowing fast assembly without sacrificing reliability.
Solution Approach 2:
The optical visibility change of the transparent resin cover provides real-time feedback on assembly completeness. Users can immediately see if the cover is properly locked or in a half-fitting state, enabling quick correction without complex detection systems.
Data Source
AI summary
A fusible link unit includes a conductive bus-bar having a fusible portion, a resin housing molded integrally with the bus-bar and including a locking projection, and an exposing window portion for exposing the fusible portion, such that the resin cover is capable of being locked to the locking projection so as to cover the fusible portion, where a half-fitting prevention projection is provided at a periphery of the exposing window portion to prevent half-fitting while suppressing an increase in projection costs.