Modular Bus Bar Forming Die for Vehicle Configurations

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Solution Overview

Problem

The existing bus bar manufacturing process requires multiple dies for different vehicle types, leading to increased costs due to the need for various shapes and configurations, including differences between left-hand and right-hand drive vehicles, resulting in unnecessary production and storage of unmodified die blocks.

Innovation Solution

A modular bus bar forming die system with replaceable upstream-side, downstream-side, and fixation portion die blocks allows for shaping a wide variety of bus bar shapes by selecting and replacing only the necessary die blocks, reducing waste and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple dies are used for different vehicle types, then various bus bar shapes can be produced, but costs of forming the bus bar forming dies increase

Engineering Contradiction:

Improvebus bar shape varietyVSAvoiddie block quantity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The bus bar forming die is divided into multiple independent die blocks (first die block for upstream-side fuse-element portion, second die block for downstream-side fuse-element portion, third die block for fixation portions). Each die block can be independently selected and replaced based on the required bus bar configuration, allowing various shapes to be produced without increasing the total number of dies needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each die block is designed to perform multiple functions across different vehicle types. The same die block can be used for both left-hand drive and right-hand drive vehicles by simply replacing it with another die block when needed, making the die system universally applicable to multiple vehicle configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If one type of bus bar is applied to one vehicle type, then specific vehicle requirements are met, but costs of forming the bus bar forming dies increase due to producing multiple die types

Engineering Contradiction:

Improvevehicle-specific bus bar performanceVSAvoiddie block production

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The die system is segmented into functional modules (upstream-side die block, downstream-side die block, fixation portion die block) that can be independently selected. This allows the production of vehicle-specific bus bars using only the necessary die blocks, avoiding the need to produce and store complete sets of dies for every vehicle type.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of producing and storing multiple complete die sets for different vehicle types, the system allows for replacing only the necessary die blocks when vehicle type changes are required. This reduces waste by avoiding the production of unnecessary die blocks and enables recovery/reuse of common die blocks across different vehicle applications.

Inventive Principle:

Principle #34Discarding and recovering

3Adaptability or versatility

If multiple dies are produced for different vehicle configurations, then all vehicle types can be accommodated, but unnecessary die blocks are produced and stored uselessly

Engineering Contradiction:

Improvevehicle type coverageVSAvoiddie block waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The die system is divided into independent die blocks that can be selectively assembled. This segmentation eliminates the need to produce complete die sets for every vehicle type, as only the required die blocks need to be produced and stored, significantly reducing material waste.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The die blocks are designed to be universally applicable across multiple vehicle types. A single die block can serve multiple vehicle configurations, reducing the total number of die blocks that need to be produced and stored, thereby minimizing waste.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9558901B2Method of manufacturing bus bar

Publication Date: 2017.01.31 YAZAKI CORP

AI summary

A bus bar forming die (1) includes an upstream-side die block (25) configured to shape an upstream-side fuse-element portion (9) of a bus bar (23), a downstream-side die block (27) configured to shape a downstream-side fuse-element portion (15) of the bus bar (23), and a fixation portion die block (29) configured to shape fixation portions (21) of the bus bar (23). The upstream-side die block (25), the downstream-side die block (27), and the fixation portion die block (29) are configured to shape the bus bar (23) while placed in respective predetermined positions. Each of the upstream-side die block (25), the downstream-side die block (27), and the fixation portion die block (29) is replaceable in accordance with an intended shape of the bus bar (23).