Line Spring Jack Groove Positioning Plug Assembly
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Solution Overview
Problem
The assembly of positioning plugs in line spring jacks is complicated due to the need for hole enlargement and requires specialized equipment, making it difficult to achieve the required insertion-withdrawal force, frequency, and contact resistance for metal clip terminals in industrial connectors.
Innovation Solution
A line spring jack design with a groove in the jack body and a positioning plug having two portions, where the first portion fits tightly in the groove and the second portion is in the plug hole, allowing for easier assembly and alignment of line spring wires between the jack cap and jack body, reducing the need for complex tooling and enhancing the insertion-withdrawal mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the groove caliber is made larger than the jack body diameter to facilitate positioning plug assembly, then the assembly process becomes simpler, but the positioning plug requires hole enlarging equipment and stamping process which increases device complexity
Solution Approach 1:
The positioning plug is designed with a nested structure where the first portion fits into the groove and the second portion extends into the plug hole. This nested configuration allows the positioning plug to be assembled without hole enlarging equipment, as the groove provides a receptacle that accommodates the positioning plug's first portion while the second portion aligns with the plug hole.
Solution Approach 2:
The positioning plug is divided into two distinct portions: a first portion that fits into the groove and a second portion that extends into the plug hole. This segmentation allows each portion to serve a specific function - the first portion provides stable positioning within the groove while the second portion enables alignment and insertion into the plug hole, eliminating the need for complex hole enlarging processes.
2Ease of manufacture
If the positioning plug is stamped to enlarge the hole for assembly, then the positioning plug can be assembled into the groove, but the assembly process becomes more difficult and requires specialized equipment
Solution Approach 1:
The groove is pre-formed in the jack body with a caliber larger than the jack body diameter, creating a ready-made receptacle for the positioning plug's first portion. This preliminary action eliminates the need for stamping or hole enlarging during the positioning plug assembly process, as the groove is already prepared to accommodate the positioning plug.
3Strength
If the positioning plug external diameter is larger than the groove caliber, then the positioning plug can engage the groove, but hole enlarging equipment and process are required which complicates manufacturing
Solution Approach 1:
The positioning plug's first portion is nested within the groove, providing strong engagement and positioning. The nested configuration ensures that the positioning plug is securely held in place while allowing for standard manufacturing processes without hole enlarging equipment.
Data Source
Figure 1
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Figure 4~5
AI summary
A line spring jack and an assembling method thereof. The line spring jack comprises a jack body (1), a jack cap (4), a line spring wire (3) and a positioning plug (2). The jack body comprises a plug hole (11); the line spring wire is located in the plug hole; the jack cap is connected to one end of the jack body; the jack cap comprises a through hole (42) connected to the plug hole; one end of line spring wire is clipped in a gap formed between the jack cap and the jack body. The plug hole comprises a groove (12) in the bottom; the caliber of the groove is smaller than that of the plug hole; the positioning plug includes a part in the groove and a part in the plug hole, the part in the groove is tightly matched with the groove.