Relay Connector With Defining Wall For Generator Junction Box
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing connection mechanisms for electric parts in generator operating machines face issues with poor workability due to exposed terminals that can bend during assembly, and water intrusion into the switch portion, leading to potential generator malfunctions.
Innovation Solution
An electric part connection mechanism using a cylindrical relay connector with a defining wall, fitting portion, relay terminals, and a waterproof sheet to prevent water intrusion and simplify assembly by guiding terminal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the voltage switching switch is fixed to the operation panel with exposed male terminals, then the electrical connection can be established, but the terminals may bend during assembly and the assembling workability deteriorates
Solution Approach 1:
The invention divides the connection system into distinct segments: the voltage switching switch with female terminals mounted on the operation panel, and the seatbelt connector with male terminals as a separate assembly. This segmentation allows the terminals to be protected within their respective housings during assembly, preventing bending while maintaining reliable electrical connections when mated.
Solution Approach 2:
The invention introduces the seatbelt connector as an intermediary component between the voltage switching switch and the generator circuit. This intermediary connector provides a protected interface with male terminals enclosed in a housing, preventing direct exposure and bending while establishing reliable electrical connections to the circuit board.
2Ease of operation
If the movable switch is provided with a gap for movement, then the switch can operate, but water may intrude into the switch portion through the gap causing generator malfunction
Solution Approach 1:
The invention employs a waterproof sheet as a flexible barrier that covers the gap between the movable switch and operation panel. This thin film maintains the operational gap for switch movement while preventing water intrusion, thus protecting the electrical components from water damage while preserving switch functionality.
Solution Approach 2:
The waterproof sheet acts as an intermediary element between the movable switch and the external environment. It allows the switch to maintain its movement capability while blocking the harmful factor (water) from reaching the electrical components through the necessary gaps.
3Reliability
If multiple seatbelt connectors are used to connect terminals, then the electrical connections can be established, but the assembling process becomes complex and time-consuming
Solution Approach 1:
The invention merges multiple connection functions into a single integrated seatbelt connector assembly. The connector combines multiple male terminals and connection functions in one unit that can be installed as a single component, reducing the number of assembly steps and improving productivity while maintaining reliable electrical connections to the generator circuit.
Data Source
AI summary
Provided is a connection mechanism which connects a switch portion 20 of a generator 1 to an assembling terminal 11 of a junction box 10 having plural female terminals 12 connected to a generator circuit 13 via a relay connector 30, wherein the relay connector 30 forms a defining wall 31 inside a cylindrical body so that a fitting portion 32 is provided at one side of the defining wall 31 so as to be fitted to the switch portion 20, and plural relay terminals are attached to the other side so as to be connected to the plural female terminals 12, and wherein holes 35 are provided in the defining wall so as to respectively face the front ends of the relay terminals 33. Accordingly, the switch portion 20 and the assembling terminal 11 are integrally and directly connected to each other via the relay connector 30.