Junction Box Cassette Block Rear-Loading Jig Mechanism
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Solution Overview
Problem
In the manufacturing of electrical junction boxes, electric wires are often damaged or disconnected during the attachment of cassette blocks due to the use of hand tools, which can cause quality issues.
Innovation Solution
The electrical junction box design incorporates a jig engagement portion in the cassette blocks, allowing a device to be inserted from the second opening and engaged with the jig engagement portion, enabling the cassette blocks to be drawn into the frame without pushing, thus preventing damage to the electric wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hand tools are used to push cassette blocks into the frame, then the attachment work can be performed, but electric wires may be damaged or disconnected
Solution Approach 1:
Instead of pushing the cassette block from the front (which risks damaging wires), the invention applies force from the rear by inserting a rod through the second opening. This reverses the direction of force application, allowing the cassette block to be pushed into the frame without the pushing force contacting the electric wires that extend from the front.
Solution Approach 2:
A rod serves as an intermediary tool that transmits force from the operator to the cassette block through the second opening. This intermediary allows force application without direct contact between the operator's hand/tool and the electric wires, preventing damage while enabling the attachment operation.
2Force
If hand tools are used to push cassette blocks, then pushing force can be applied, but the size of the tool may cause it to push against electric wires
Solution Approach 1:
The harmful element (the large hand tool that risks contacting wires) is extracted from the system. Instead of using a large hand tool from the front, the invention uses a thin rod inserted from the rear opening, which can apply force without risking contact with the electric wires.
Solution Approach 2:
The force application is moved from the front dimension (where wires are present) to the rear dimension (second opening). By changing the spatial dimension from which force is applied, the invention eliminates the risk of tool contact with wires while maintaining the necessary pushing force.
3Productivity
If cassette blocks are temporarily inserted from the first opening, then the attachment process can proceed, but wires are exposed to potential damage during pushing
Solution Approach 1:
The invention inverts the force application direction by pushing from the rear (second opening) rather than from the front (first opening). This allows the cassette block to be properly attached while the wires naturally extend forward without being in the path of the pushing force, maintaining both efficiency and quality.
Data Source
AI summary
An electrical junction box includes a frame and a cassette block. The frame has a side wall, the frame having a first opening and a second opening provided at two ends of the side wall. The cassette block is to be attached to the frame from the first opening along a first direction and electric wires are drawn out along a second direction when the cassette block is attached to the frame, the first direction being a direction toward the second opening from the first opening, the second direction being another direction toward the first opening from the second opening. The cassette block has a jig engagement portion configured such that a jig inserted into the cassette block from a side of the second opening engages with the jig engagement portion and the cassette block is drawn into the frame by the jig moving in the first direction.