Modular Electrical Junction Box with Detachable Cassettes
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Solution Overview
Problem
Cassette type electrical junction boxes are designed individually for each vehicle or grade, limiting their versatility and requiring manual U-turn connections for relays and fuses, which decreases productivity.
Innovation Solution
A modular electrical junction box design featuring a common relay block, individual corresponding relay block, common power supply block, and individual semiconductor module, with bus bars and guide/locking portions for easy assembly and automatic electrical connections, allowing for customization for different vehicles and grades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cassette type electrical junction boxes are designed individually for each vehicle or grade, then the electrical junction box can be customized for specific vehicle requirements, but the versatility and common usage capability deteriorates
Solution Approach 1:
The electrical junction box is divided into a housing and multiple detachable cassettes. Each cassette is a self-contained module that can be independently designed, manufactured, and replaced. This segmentation allows different cassette configurations to be used with the same housing, enhancing versatility while maintaining a standardized base structure.
Solution Approach 2:
The housing is designed with universal features including standardized opening/closing mechanisms,统一的 storing chambers, and common mounting structures. This universality allows the same housing to accommodate different types and configurations of cassettes across various vehicle models and grades, improving common usage capability.
2Quantity of substance
If a large number of relays or fuses are stored in the electrical junction box, then the electrical connection capability is improved, but the productivity deteriorates due to manual U-turn connection work
Solution Approach 1:
Relays and fuses are pre-assembled into complete cassette modules before being installed in the housing. The cassettes are prepared in advance with all necessary electrical connections and components already in place, eliminating the need for manual U-turn connections during final assembly. This preliminary preparation significantly improves productivity.
Solution Approach 2:
Multiple relays and fuses are nested within compact cassette structures, allowing a large quantity of electrical components to be stored in an organized manner within the housing. The nested arrangement maximizes space utilization while maintaining accessibility and simplifying assembly operations.
3Ease of operation
If the electrical junction box housing includes multiple storing chambers for different blocks, then the organization and accessibility are improved, but the device complexity increases
Solution Approach 1:
The housing is segmented into multiple storing chambers, each dedicated to specific types of cassettes or components. This segmentation organizes the internal space logically, improving accessibility by allowing technicians to quickly locate and access specific components without disassembling the entire structure.
Solution Approach 2:
The storing chambers are arranged in a three-dimensional configuration within the housing, utilizing vertical and horizontal space efficiently. This spatial arrangement allows multiple chambers to coexist without excessive structural complexity, maintaining ease of access while optimizing the use of available volume.
Data Source
AI summary
An electrical junction box includes: an electrical junction box housing; and a common relay block, an individual corresponding relay block, a common power supply block, and an individual corresponding semiconductor module. The common relay block, the individual corresponding relay block, the common power supply block, and the individual corresponding semiconductor module are attached to the electrical junction box housing.