Outdoor Unit Lead Wire Assembly for Physical Miswiring Prevention
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Solution Overview
Problem
Existing air-conditioning outdoor unit assembly processes still face issues with wiring mistakes despite the use of cluster blocks of different colors, as connections can be made to any conductive pins, leading to potential miswiring.
Innovation Solution
The air-conditioning outdoor unit incorporates lead wire groups with varying lengths and end connectors, including cluster blocks and flag-shaped terminals, which are detachably connected to specific conductive pins using relay connectors, ensuring unique and correct connections by differing lengths and shapes, preventing physical miswiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead wire groups have varying lengths and different end connectors, then wiring mistakes are physically prevented, but assembly complexity increases
Solution Approach 1:
The patent applies self-service by designing the lead wire groups and end connectors so that the assembly process guides itself through the unique length and connector configurations. The asymmetric design automatically prevents incorrect connections, as the physical dimensions and connector geometries do not match wrong targets. This self-guiding mechanism reduces the need for complex assembly instructions or quality control checks, as the system itself prevents errors through its design.
2Adaptability or versatility
If lead wire groups are cut into two parts with relay connectors, then flexibility and error prevention are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing lead wire groups into two separate parts that are connected through relay connectors. This segmentation allows for greater flexibility in routing and connecting lead wires to different glass terminals, as each segment can be independently configured. The relay connectors serve as intermediate connection points that maintain the unique length and connector characteristics, enabling the lead wire groups to adapt to different terminal configurations while preventing miswiring through the segmented design.
Data Source
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AI summary
An air-conditioning outdoor unit includes a compressor having a plurality of terminals each including a plurality of conductive pins. The outdoor unit includes a plurality of lead wire groups provided for the respective terminals and each including a plurality of lead wires connecting a control board to the plurality of conductive pins, and a plurality of different end connectors provided for the respective lead wire groups and each attached to an end portion of the lead wire group adjacent to the plurality of conductive pins. The lead wire groups are each connected by the end connector to the plurality of conductive pins and cut into two parts at a given point in a longitudinal direction. The two parts of the lead wire group are detachably coupled together at the given point by a pair of relay connectors. A length from the control board to the given point and a length from the given point to the end connector differ from one lead wire group to another.