Power Filter Terminal Block Clamping for Assembly
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Solution Overview
Problem
The manual winding and welding processes in power filters are time-consuming and labor-intensive, limiting production capacity and increasing costs.
Innovation Solution
A power filter design featuring a circuit board module with connect holes, insulating base with angled connect terminals, and an inductor, allowing for direct electrical connections and reduced manual labor, with the inductor's wire clamped by the terminals to form a circuit loop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual winding and welding processes are used for electronic components, then connection reliability is improved, but production time and labor costs increase significantly
Solution Approach 1:
The patent replaces manual mechanical winding and welding processes with an automated terminal block connection system. The terminal blocks provide pre-configured connection points that accept wire inputs through simple insertion and crimping operations, eliminating the need for manual winding around components and precise welding operations. This mechanical substitution maintains connection reliability while dramatically improving production speed and capacity.
Solution Approach 2:
The terminal blocks are designed with self-aligning features and built-in crimping mechanisms that automatically secure the wire connections without requiring manual intervention for each connection point. The modular design allows workers to simply insert wires into the terminal blocks, which then self-secure through the crimping structure, reducing both time and skill requirements while maintaining reliable connections.
2Manufacturing precision
If manual winding and welding processes are used for electronic components, then connection precision is improved, but labor costs and operating time increase
Solution Approach 1:
The terminal blocks are pre-configured with connection points, crimping structures, and mounting holes before assembly. This preliminary preparation ensures that during the assembly process, workers simply need to insert wires into the pre-positioned terminal blocks, which then automatically provide precise alignment and secure connection through the built-in crimping mechanism, eliminating the need for time-consuming manual positioning and securing operations.
Solution Approach 2:
The patent replaces precision manual welding operations with a mechanical crimping system integrated into the terminal blocks. This mechanical substitution provides consistent, repeatable connection precision through the standardized crimping structure, eliminating variability in manual welding quality while significantly reducing the time required for each connection.
3Reliability
If complex manual assembly processes are used, then connection reliability is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple functions into the terminal blocks: connection points for wire insertion, crimping structures for securing wires, mounting features for attachment to the circuit board, and electrical connection pathways. This consolidation of functions into single integrated components simplifies the overall assembly process while maintaining reliable connections, as workers deal with unified terminal block units rather than separate components requiring multiple assembly steps.
Solution Approach 2:
The terminal blocks are designed as universal connection components that can accommodate different wire types and sizes while providing consistent connection reliability. The standardized design allows the same terminal block structure to serve multiple connection points throughout the device, reducing the variety of unique components needed and simplifying the assembly process through repetition of proven reliable connection mechanisms.
Data Source
Figure 1
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AI summary
A power filter 1 is provided, including a circuit board module 10, an insulating base 20, several connect terminals 31, and an inductor 40. The circuit board module includes a circuit board and several electronic components, wherein the circuit board forms several connect holes thereon and the electronic components are electrically connected to the circuit board. The connect terminals 31 are fixed on the insulating base 20 and each has a connecting part and a clamping part, wherein the connecting parts are joined with the connect holes of the circuit board. The inductor 40 includes at least one wire 42 with both terminals 42A clamped by the clamping parts, and the wire is electrically connected to the circuit board module through the connecting parts.