Lug Mounting Prearrangement for Retaining Screw Alignment
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Solution Overview
Problem
The existing methods for mounting earthing cable lugs on a retaining screw in motor vehicles are complex and prone to errors, especially when dealing with multiple lugs, as they require sequential threading and fanning out, which can lead to spatial misalignment and operational safety issues.
Innovation Solution
A prearrangement and mounting aid that combines lugs on a cable tree, using a distributor with aligned fixing holes and a centring element, allowing simultaneous placement on a retaining screw, with a detachable mounting aid that includes snap-in fasteners and a sealing element to prevent misalignment and ensure secure mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lugs are mounted sequentially on the retaining screw, then each lug can be individually positioned, but the mounting process becomes complex and time-consuming
Solution Approach 1:
The lugs are pre-assembled on the cable tree in the correct sequence and orientation before delivery to the assembly line. This preliminary arrangement eliminates the need for complex sequential mounting operations during final assembly, allowing workers to simply attach the pre-configured lug assembly to the retaining screw.
Solution Approach 2:
Multiple lugs that would normally be mounted separately are combined into a single pre-assembled unit on the cable tree. This merging of multiple mounting operations into one integrated component reduces both the complexity and time of the mounting process while ensuring proper spacing and orientation of all lugs.
2Reliability
If multiple lugs are mounted on the same retaining screw, then cable tree functionality is achieved, but spatial misalignment and superposition of crimp sections occur
Solution Approach 1:
The cable tree incorporates lug holders with specific geometric features (such as angled surfaces or positioning elements) that ensure each lug is held in its correct spatial orientation and position. This localized structural design prevents misalignment and superposition by providing unique positioning characteristics for each lug location.
Solution Approach 2:
The cable tree structure acts as an intermediary component that holds multiple lugs in their correct positions before final attachment to the retaining screw. This intermediary fixture ensures proper spatial distribution and alignment of all lugs, preventing misalignment issues during the mounting process.
3Adaptability or versatility
If the number of lugs varies with vehicle equipment, then vehicle-specific configurations are achieved, but mounting errors occur due to oversight
Solution Approach 1:
Different lug holders or lug positions on the cable tree are marked with distinct color codes or visual indicators that correspond to specific vehicle equipment configurations. This visual coding system allows workers to quickly identify which lugs should be installed for a particular vehicle type, preventing oversight and ensuring complete and correct mounting.
Solution Approach 2:
The cable tree design includes features that provide immediate visual or tactile feedback when all required lugs are correctly positioned and attached. This feedback mechanism (such as alignment indicators, interlocking features, or checklist systems) ensures that no lugs are overlooked during the mounting process, regardless of the vehicle's equipment configuration.
Data Source
AI summary
A prearrangement for mounting lugs (12) on a retaining screw (24) includes a distributor (10) and at least two lugs (12) each with a fixing hole (13). The lugs are each inserted in the distributor in such a way that the fixing holes are substantially in alignment with each other. A mounting aid (16) is connected detachably to the distributor and has a protruding centering element (20) having a cross section substantially corresponding to the cross section of the retaining screw. The centering element passes through the fixing holes in the lugs. The end (30) of the centering element facing the retaining screw has an engagement section for engagement with the screw.