Gas Sensor Metal Terminal Contact Interference
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The fitting and welding of male and female terminal members in gas sensors often result in inefficiencies due to contact issues and potential gaps, leading to reduced work efficiency and welding stability.
Innovation Solution
A metal terminal design for gas sensors featuring a front-side terminal member with a female connection portion and a rear-side terminal member with a male connection portion, where the female connection portion has an insertion port to prevent initial contact and terminal contact portions to ensure proper alignment and contact, enhancing the connection and welding stability without the need for additional jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a male terminal member and a female terminal member are fitted together, then electrical connection is achieved, but the outer peripheral surface of the male terminal member and the inner peripheral surface of the female terminal member may come into contact, causing deterioration in fitting work efficiency
Solution Approach 1:
The terminal connection structure is divided into three distinct segments: the male terminal member, the female terminal member, and an intermediate member positioned between them. This segmentation prevents direct contact between the male and female terminal members, eliminating interference during fitting work while maintaining electrical connection through the intermediate member.
Solution Approach 2:
An intermediate member is introduced as a mediator between the male terminal member and the female terminal member. This intermediate member has an outer peripheral surface that prevents contact between the male and female terminal members during insertion, thereby improving fitting work efficiency without compromising electrical connection.
2Strength
If the male terminal member and the female terminal member are fixed by welding, then mechanical strength is achieved, but a gap may be formed at the contact portion, causing welding failure
Solution Approach 1:
The intermediate member serves as a mediator that ensures proper alignment and contact between the male and female terminal members. By preventing premature contact and maintaining precise positioning, the intermediate member eliminates gaps at the contact portion, enabling successful welding and achieving both mechanical strength and welding stability.
Solution Approach 2:
The intermediate member performs preliminary positioning and alignment of the male and female terminal members before welding occurs. This preliminary action ensures that the contact portions are properly aligned and free from gaps, creating optimal conditions for successful welding.
Data Source
AI summary
A metal terminal includes a front-side terminal member and a rear-side terminal member. The front-side terminal member includes a female connection portion, and the rear-side terminal member includes a male connection portion. The female connection portion has an insertion port in which the male connection portion is inserted. The insertion port is formed in a shape that prevents the insertion port and the male connection portion from coming into contact with each other when the male connection portion is inserted therein. The female connection portion includes a terminal contact portion which brings the male connection portion and the female connection portion into contact with each other by pressing the male connection portion toward the female connection portion inside the female connection portion.