Orthogonal Hinge Wire Arrangement Body for Busbar Sealing

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Solution Overview

Problem

The existing busbar module in power-supply units for hybrid and electric automobiles faces issues where the lid portion that seals the wire arrangement groove portion can be opened due to tensile forces applied to the wire drawing piece, leading to potential wire exposure and damage.

Innovation Solution

The wire arrangement body is designed with a wire arrangement groove portion and a lid portion connected by a first hinge, and a wire drawing piece connected by a second hinge with a rotation axis orthogonal to the first hinge, preventing the lid portion from being opened by tensile forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the lid portion is connected to the wire arrangement groove portion by a hinge to enable opening and closing, then the ease of operation is improved, but the reliability deteriorates because the lid portion can be opened by tensile forces applied to the wire drawing piece

Engineering Contradiction:

Improveease of opening and closing lid portionVSAvoidreliability of lid portion sealing

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The wire arrangement body is segmented into multiple functional portions: the wire arrangement groove portion, the lid portion, and the wire drawing piece. This segmentation allows each component to perform its specific function independently while maintaining overall system reliability through proper structural design of the connections between segments.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hinge connection is designed to rotate about an axis that is perpendicular to the direction of the tensile force applied to the wire drawing piece. This dimensional orientation change ensures that the tensile force does not generate a moment that would cause the lid portion to open, thereby maintaining sealing reliability while preserving operational ease.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of operation

If the lid portion is made movable to allow wire access, then the ease of operation is improved, but the protection of wires from external contact and impact deteriorates

Engineering Contradiction:

Improveease of wire accessVSAvoidwire exposure to external contact and impact

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The lid portion is pre-configured with a hinge connection that maintains contact with the wire arrangement groove portion during normal operation. This preliminary protective arrangement ensures wires are protected from external contact and impact while still allowing controlled access when needed, as the lid can be opened deliberately through the hinge mechanism.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The hinge connection acts as an intermediary mechanism between the lid portion and the wire arrangement groove portion. It mediates between the need for wire access and the need for protection, allowing controlled opening while maintaining sealing during normal operation, thus protecting wires from harmful external factors.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If the wire drawing piece is connected to the lid portion by a hinge, then the ease of operation is improved, but the stability of the structure deteriorates because tensile forces can open the lid portion

Engineering Contradiction:

Improveease of wire drawing operationVSAvoidstructural stability of lid portion

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The hinge connection geometry is designed asymmetrically such that the rotation axis is perpendicular to the tensile force direction. This asymmetric design creates a mechanical configuration where the tensile force applied during wire drawing does not translate into a moment that would destabilize the lid portion connection, thereby maintaining structural stability while preserving operational ease.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The perpendicular hinge axis design creates a counterbalancing geometric relationship that offsets the destabilizing effect of tensile forces. The structural configuration inherently resists the opening moment through its geometry, providing passive stability without requiring additional active counterbalancing mechanisms.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Data Source

PatentUS9608250B2Wire arrangement body, busbar module and power-supply unit

Publication Date: 2017.03.28 YAZAKI CORP

AI summary

A wire arrangement body includes: a wire arrangement groove portion of a groove shape that receives one or more wires; a lid portion that is rotatably connected to the wire arrangement groove portion about a first hinge and covers the wire arrangement groove portion so as to seal a groove opening of the wire arrangement groove portion; and a wire drawing piece that is rotatably connected to the lid portion about a second hinge. The wire arrangement body is provided so that a rotation axis of the second hinge crosses at a right angle to a rotation axis of the first hinge.