LCDI Wire Bundle Assembly for Tool-Free Leakage Detection
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Solution Overview
Problem
The assembly of conventional leakage current detection interrupter (LCDI) devices is time-consuming and inefficient, requiring multiple parts and tools to assemble, which complicates the process and reduces production efficiency.
Innovation Solution
The LCDI device incorporates a shell with a base and upper cover, a movement unit with connecting conductors and fastener members, and a wire bundle assembly with shield detection lines and terminals, allowing for tool-free assembly and secure electrical connections through positioning holes and resilient tabs, along with a fire shield made of high-temperature resistant materials to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual parts and tools are used for assembly, then the device structure is flexible and reliable, but the assembly process becomes time-consuming and inefficient
Solution Approach 1:
The patent integrates multiple separate components into a unified modular assembly. The movement unit combines the interrupter mechanism, connecting conductors, and fastening structures into a single integrated module that can be installed as one unit, dramatically reducing assembly time while maintaining the reliability of individual components
Solution Approach 2:
The movement unit is pre-assembled with connecting conductors and fastening structures already in place before installation into the LCDI device. This preliminary preparation of sub-assemblies enables quick installation without requiring multiple separate assembly steps during final device assembly
2Manufacturing precision
If tools are used to fix component positions, then the assembly is precise and secure, but the assembly process requires additional tools and time
Solution Approach 1:
The movement unit incorporates self-aligning and self-retaining features including positioning protrusions that fit into corresponding recesses, and resilient tabs that automatically secure components upon insertion. These self-service mechanisms eliminate the need for external tools to fix component positions while ensuring precise and secure assembly
Solution Approach 2:
Positioning protrusions and recesses act as intermediary structures that guide and secure component positions during assembly. The resilient tabs serve as intermediaries that provide automatic retention and positioning feedback, ensuring precise component placement without requiring external tooling
Data Source
AI summary
An LCDI device includes a shell, a movement unit, and a wire bundle assembly. The shell includes a base and an upper cover connected to each other. The movement unit is disposed in the base, and includes at least one connecting conductor. A first end of the wire bundle assembly is disposed in the upper cover and includes at least one shield detection line, where the shield detection line is electrically coupled to the connecting conductor. The shield detection line includes a connecting terminal at the first end of the wire bundle assembly which is configured to received and retain the connecting conductor inserted therein. The structure of the LCDI enables fast and secure assembling of the wire bundle assembly and movement unit, and eliminates the need for internal re-adjustment of the shield detection lines after assembling, which promotes automation of large scale production.