Pushrod-Clamped Fuse Module for Compact Pre-Fuse Box Service
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Solution Overview
Problem
Existing pre-fuse boxes in automotive engine compartments are large and cumbersome, requiring significant space and making the installation and removal of fuses time-consuming due to conventional mechanical fasteners.
Innovation Solution
A fuse module with a housing made of electrically insulating material, a movable pushrod, and a busbar that can be easily extended or retracted to clamp and unclamp fuses, eliminating the need for removable fasteners for installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical fasteners (nuts, bolts) are used to secure fuses in pre-fuse boxes, then the fuses can be securely held in place, but the installation and removal of fuses becomes cumbersome and time-consuming
Solution Approach 1:
The busbar is designed with a flexible portion that can dynamically change position between retracted and extended states. When the pushrod extends, it pushes the flexible portion to extend, which in turn pushes the rigid portion to engage with the fuse plate and clamp the fuse. When the pushrod retracts, the flexible portion returns to its original position, releasing the clamp. This dynamic mechanism eliminates the need for separate fasteners while enabling quick fuse installation and removal.
2Reliability
If conventional mechanical fasteners are used in pre-fuse boxes, then secure fuse mounting is achieved, but the overall size of the pre-fuse box increases
Solution Approach 1:
The clamping function is merged into the busbar itself through the flexible portion that can be pushed to extend and engage with the fuse plate. This integration eliminates the need for separate fasteners (nuts, bolts, clips) that would otherwise be required to secure fuses. The busbar serves both its electrical conduction function and the mechanical clamping function, reducing the overall space required in the pre-fuse box.
3Volume of moving object
If a compact pre-fuse box design is implemented to save space, then space requirements are reduced, but the installation and removal of fuses becomes more difficult
Solution Approach 1:
The dynamic pushrod mechanism allows for easy fuse installation and removal despite the compact design. The pushrod can be extended to push the flexible portion of the busbar, which automatically clamps the fuse in place during installation. For removal, the pushrod is retracted, releasing the clamp. This dynamic action mechanism maintains ease of operation while achieving a compact pre-fuse box design that saves valuable engine compartment space.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fuse module provides a compact and efficient solution for fuse installation and removal, reducing installation time and space requirements while ensuring secure electrical connections.
Implementation Method 1
a movable pushrod extending through the rear wall of the housing and having a head portion disposed adjacent a rigid portion of the busbar for moving the rigid portion of the busbar between a retracted position and an extended position
Data Source
AI summary
A fuse module including a housing, a busbar disposed within the housing adjacent an interior surface of a rear wall of the housing, a terminal extending through a front wall of the housing and having a fuse coupling portion disposed within the housing adjacent an interior surface of a front wall of the housing and a conductor coupling portion protruding from an exterior surface of the front wall of the housing, and a movable pushrod extending through the rear wall of the housing and having a head portion disposed adjacent a rigid portion of the busbar for moving the rigid portion of the busbar between a retracted position, the rigid portion of the busbar located near the interior surface of the rear wall, and an extended position wherein the rigid portion of the busbar is located further from the interior surface of the rear wall relative to the retracted position.