Power Cable Connector Ribs for Strength Without Size Increase
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connecting structures between terminal blocks and power cables in electric vehicles face challenges in increasing strength without enlarging the size of the connector and terminal block, which is crucial due to the high power requirements and stiffness of the cables.
Innovation Solution
The solution involves a connecting apparatus with a connector and terminal block design that incorporates first and second ribs, where one rib is positioned in a recess of the other, intersecting each other to enhance strength while minimizing size, and includes a recess on the first rib to prevent incorrect connection and reduce thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ribs are added to increase the strength of the connector and terminal block, then the structural strength is improved, but the size of the connector and terminal block increases
Solution Approach 1:
The first rib of the connector is inserted into the recess of the second rib of the terminal block, creating a nested structure where one rib is positioned within the recess space of the other. This nesting arrangement allows the ribs to occupy the same spatial envelope without increasing the overall dimensions of the connector and terminal block, while still providing the strength-enhancing benefits of the rib structures.
Solution Approach 2:
The invention utilizes the recess feature to create a three-dimensional arrangement where the ribs intersect in space rather than extending in the same plane. By positioning one rib within the recess of the other, the structure transitions from a two-dimensional planar arrangement to a three-dimensional spatial configuration, maximizing strength within limited dimensional space.
2Volume of moving object
If the connector and terminal block are made more compact to reduce size, then the volume is reduced, but the strength may be compromised
Solution Approach 1:
The nested arrangement of the first rib within the recess of the second rib allows both ribs to be positioned in a compact configuration without requiring additional space. This nesting enables the maintaining of enhanced structural strength through the rib structures while keeping the overall volume of the connector and terminal block compact and minimized.
3Strength
If multiple ribs are provided to enhance strength, then the structural integrity is improved, but the complexity of the structure increases
Solution Approach 1:
The invention combines the functions of multiple ribs into a compact nested arrangement where the first rib and second rib work together in an intersecting configuration. Rather than adding ribs as separate, independent elements that would increase complexity, the ribs are merged into a coordinated structure where one rib is positioned within the recess of the other, achieving enhanced strength with minimal increase in structural complexity.
Data Source
AI summary
The cables are configured to supply electric power from an inverter to a motor. The cables include a connector and plural terminals fixed to the connector. A housing of the connector includes a first rib, provided between the adjacent terminals, connecting mutually facing surfaces of the housing. The terminal block is attached to an enclosure of the inverter or motor. The terminal block includes plural retaining walls, each of which encloses and retains a nut. The terminal block includes a second rib connecting adjacent retaining walls. One of the first and second ribs includes a recess. The connector is connected to the terminal block when each of the terminals is fastened to the terminal block with a bolt and the nut. The other of the first and second ribs is disposed in the recess and the ribs intersect when the connector is connected to the terminal block.