Relay Module Assembly for Automotive Electrical Centers
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Solution Overview
Problem
Existing electrical distribution centers in automobiles require mechanical assistance for assembling plug-in components, such as relays, which complicates the installation process.
Innovation Solution
A relay module comprising a lower base with a tray and depending shroud, a printed circuit board assembly with relays and terminals, and a cover with latch means, designed to be easily plugged into a housing with a lock bar mechanism, allowing for secure and efficient assembly without mechanical assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If plug-in relays are individually installed into the electrical distribution center, then each relay can be independently replaced and maintained, but mechanical assistance is required for assembly which increases installation complexity
Solution Approach 1:
Multiple individual relays are merged into a single relay module assembly that includes a circuit board with multiple relay sockets and relay components pre-mounted and connected. This consolidation allows the entire assembly to be installed as one unit into the electrical distribution center, eliminating the need for mechanical assistance while preserving the ability to replace individual relays by removing the entire module.
2Ease of operation
If multiple individual relays are installed separately, then each relay can be independently accessed, but the installation process becomes time-consuming and less efficient
Solution Approach 1:
Multiple relays are pre-mounted, wired, and tested on a circuit board before being assembled into a complete relay module. This preliminary assembly allows all relays to be installed simultaneously as a single unit into the electrical distribution center, dramatically improving assembly efficiency while maintaining easy accessibility to each relay through the modular design.
3Device complexity
If a sub-assembly of all components is plugged into the electrical distribution center, then assembly is simplified, but mechanical assistance is still required and the housing area must accommodate the entire assembly
Solution Approach 1:
The relay module is segmented into a compact assembly with a circuit board containing multiple relay sockets and mounted relays, integrated with a housing that includes integrated mounting features. This segmentation creates a self-contained module that is simple to install without mechanical assistance while fitting efficiently within the electrical distribution center's housing area.
Data Source
AI summary
An electrical center includes a housing and a relay module that is disposed in a well of the housing. The relay module has a base, a printed circuit board assembly, plug in electronic components, a cover and means of coupling and latching of the base to the well in the housing. The base includes a tray having a depending shroud at one end portion. The end portion of the tray that has depending shroud has a plurality of apertures that extend through tie end portion of the tray. A plurality of terminals have first end portions that engage the printed circuit board for electrical connection to the plurality of relays and second end portions that plug into the apertures and terminate in free ends disposed in the space inside the shroud.