Lever Fitting-Type Connector Post-Insertion Assembly and Retention
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Solution Overview
Problem
The existing lever fitting-type connectors face challenges in workability during assembly due to the lever obstructing the insertion of terminals with electric wires and are structurally rigid, making it difficult to replace the lever if broken, leading to increased man-hours and costs.
Innovation Solution
A lever fitting-type connector design featuring a flange part as a coming-off-preventing mechanism, allowing the lever to be attached after terminal insertion, with a moving-guiding system and linear-symmetrically arranged fulcrum and action point projections to enhance workability and prevent lever detachment during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lever is attached to the male connector housing before terminal insertion, then the lever can provide structural support and fulcrum function, but the lever obstructs the insertion of terminals with electric wires
Solution Approach 1:
The terminal insertion is performed as a preliminary action before lever attachment. The male connector body is first inserted into the female connector housing with terminals in place, then the lever is subsequently attached to the male connector housing. This sequence eliminates the obstruction problem while maintaining structural support.
2Stability of the object's composition
If the lever is formed in a frame-shape with electric wires passed inside, then the structure is rigid and stable, but the lever cannot be replaced individually if broken
Solution Approach 1:
The lever is segmented from the connector housing into a separate, independently replaceable component. The lever is attached to the male connector housing via detachable connections (screws or snap-fit mechanisms), allowing the lever to be removed and replaced without replacing the entire connector assembly, while maintaining structural rigidity during operation.
3Ease of operation
If the lever is attached after terminal insertion, then assembly workability is improved, but the lever may come off from the connector during rotational motion
Solution Approach 1:
Terminals are inserted into the male connector body before lever attachment, improving assembly workability. The male connector body is first positioned in the female connector housing, then the lever is attached to the male connector housing. This sequence allows easy terminal installation while maintaining lever retention through proper attachment mechanisms.
Solution Approach 2:
The male connector housing serves as an intermediary component between the lever and the female connector housing. The lever is attached to the male connector housing rather than directly to the female connector housing, providing both easy access for assembly and secure retention during operation. The male connector housing acts as a stable base that prevents lever detachment while allowing post-terminal-insertion attachment.
Data Source
AI summary
A lever fitting-type connector includes a female connector, male connector and lever. The lever includes: a pair of side plates and arranged in parallel to each other, end parts of the side plates and being separated from each other having a distance therebetween; a connecting part for connecting opposite end parts of the side plates and; and fulcrum projections formed at the respective end parts of the side plates and. The lever further includes a flange part formed from an outer edge of the fulcrum projection in an outer peripheral direction. The flange part prevents the fulcrum projections from coming off from a fulcrum projection receiving part.