Electrical Junction Box Cover Slide Guide Configuration
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Solution Overview
Problem
Electrical junction boxes experience looseness and rattling issues due to inadequate slide guide configurations, leading to noise and potential damage to wire harnesses during assembly, as existing slide guides either provide insufficient or excessive play, affecting the smooth mounting of covers and wire harness management.
Innovation Solution
The electrical junction box incorporates a dual-slide guide system where first and second slide guides are positioned at different angles and locations, reducing overall play and looseness, allowing for easier initial mounting and secure final positioning of the cover, while minimizing friction and stress on wire harnesses by adjusting play angles and edge orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If slide guides are provided with dimensional allowances to enable smooth sliding operation, then ease of operation is improved, but looseness and rattling of the cover increases
Solution Approach 1:
The single slide guide is segmented into two separate slide guides positioned at different locations. The first slide guide (protrusion 12p, depression 12d) is positioned at the leading end of the cover, while the second slide guide (protrusion 14p, depression 14d) is positioned at the side surface of the cover. This segmentation allows each slide guide to contribute differently to the overall stability, with the second slide guide specifically addressing the rattling issue by providing additional constraint closer to the mounting point.
Solution Approach 2:
The solution transitions from a single-dimensional slide guide arrangement to a two-dimensional arrangement by adding the second slide guide at a different position and orientation. The first slide guide operates primarily in the sliding direction, while the second slide guide is positioned to constrain movement in both the sliding direction and the lateral direction, thereby eliminating rattling without requiring excessive dimensional allowances in the first slide guide.
2Stability of the object's composition
If dimensional allowances of slide guides are reduced to minimize looseness, then stability is improved, but ease of operation deteriorates
Solution Approach 1:
By dividing the sliding constraint function into two separate slide guides, each guide can be designed with moderate dimensional allowances. The first slide guide maintains smooth operation with appropriate play, while the second slide guide provides additional stability without requiring the first guide to have excessive constraint, thus avoiding operation difficulties.
Solution Approach 2:
Different regions of the cover are provided with different types of slide guides based on their specific functional requirements. The leading end (first slide guide location) requires smooth sliding operation with moderate allowances, while the side surface (second slide guide location) requires enhanced stability and rattling prevention. This local differentiation allows each slide guide to be optimized for its specific purpose.
3Object-affected harmful factors
If cover projecting dimension is increased to provide adequate coverage, then protection function is improved, but displacement in rattling increases
Solution Approach 1:
The addition of the second slide guide at the side surface creates a new constraint dimension that counteracts the displacement caused by the cover's projecting dimension. Even though the cover extends significantly to protect wire harnesses, the second slide guide positioned closer to the mounting point provides a counterbalancing constraint that reduces the lever arm effect and minimizes rattling displacement.
Solution Approach 2:
The constraint system is segmented into two independent slide guides that work together. The first slide guide handles the primary sliding motion, while the second slide guide specifically addresses the stability issue caused by the cover's extended projection. This segmentation allows the cover to maintain its protective projecting dimension without suffering from excessive rattling displacement.
Data Source
AI summary
An electrical junction box is provided to reduce looseness of a cover. The electrical junction box includes a box body and the cover to be slidably mounted on a lateral side of the box body from above. The cover has a front wall and a pair of left and right sidewalls connected to both left and right ends of the front wall to overlap with left and right connecting walls of the box body, providing a U-shaped cross section. The electrical junction box further includes first slide guides provided on both of the cover and the box body and second slide guides provided on both of the cover and the box body. The second slide guides are positioned in areas where the left and right sidewalls of the cover overlapping with the left and right connecting walls of the box body. Further, the second slide guides are closer to the front wall of the cover being mounted to the box body than the first slide guides.