Modular Electrical Terminal Connection with Error-Compensating Busbars
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Solution Overview
Problem
Existing electrical connection methods for motors, such as those in hybrid vehicles, are cumbersome due to the need for precise alignment of bolt insertion holes, making the connection process laborious and prone to errors.
Innovation Solution
A modular connection system featuring a movable side housing, a waiting side housing, and intermediate terminals with error-compensating busbars, allowing for precise alignment and secure fixing of power feed and motor side terminals using a fastener, thereby simplifying and improving the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolt insertion holes of power feed terminal and motor side terminal are aligned and fixed by hand, then connection reliability is improved, but operational complexity and time consumption increase
Solution Approach 1:
The connector is divided into two separate housings: a movable side housing holding the power feed terminal and a waiting side housing holding the motor side terminal. This segmentation allows each housing to be prepared independently with pre-positioned bolt insertion holes, eliminating the need for manual alignment during connection while maintaining reliable bolted fixation.
Solution Approach 2:
An intermediate terminal is introduced as a mediator component within the waiting side housing. This intermediate terminal includes both a motor side contact and a power-feed side contact, serving as an intermediary connection point that simplifies the overall connection structure and enables precise positioning of bolt insertion holes through the housing structure rather than direct terminal alignment.
2Manufacturing precision
If bolt insertion holes are precisely aligned before fixing, then connection precision is improved, but time consumption and labor burden increase
Solution Approach 1:
The bolt insertion holes in both the movable side housing and waiting side housing are pre-positioned and pre-aligned during the housing manufacturing process. This preliminary action ensures that when the two housings are connected, the bolt insertion holes are already in precise alignment, eliminating the need for time-consuming manual alignment operations during actual connection.
Solution Approach 2:
By segmenting the connector into two housings with pre-positioned bolt insertion holes, the alignment task is transferred to the manufacturing stage rather than the assembly stage. Each housing is manufactured with precisely positioned holes, and the modular design ensures automatic alignment when connected, significantly reducing connection time while maintaining high precision.
3Device complexity
If terminals are directly connected with bolt, then structure is simplified, but positioning accuracy decreases
Solution Approach 1:
An intermediate terminal is introduced as a mediator component within the waiting side housing. This intermediate terminal includes both a motor side contact and a power-feed side contact, serving as an intermediary connection point that simplifies the overall connection structure while enabling precise positioning of bolt insertion holes through the housing structure rather than direct terminal alignment.
Data Source
AI summary
Power feed terminals (50) are held in movable side housings (20), and intermediate terminals (40) are held in a waiting side housing (10). Each intermediate terminal (40) includes a power-feed side contact (42) and a motor side contact (44). A connection surface (12BS) of the waiting side housing (10) is exposed at the outer surface of a motor casing (90), and the power-feed side contacts (42) of the intermediate terminals (40) are exposed in the connection surface (12BS) of the waiting side housing (10). By connecting the housings (10, 20), contacts (51) of the power feed terminals (50) are placed on the power-feed side contact portions (42) and bolts (60) are inserted through these contacts placed one over the other to fix the terminals (40, 50) together.