Rotary Connector Terminal Holder for Multi-Axis Alignment
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Solution Overview
Problem
Existing rotary connectors face challenges in accurately positioning the external connection terminal with respect to a connection partner, particularly due to manufacturing errors, which complicates the electrical connection between steering-side and vehicle-side electric components in vehicles.
Innovation Solution
A rotary connector design that includes a movable and rotatable external connection terminal held by a terminal holder, allowing movement in both the Y and Z axes and rotation about a parallel axis, enabling flexible positioning and orientation to accommodate dimensional tolerances and manufacturing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the external connection terminal is fixed rigidly to the case, then the structure is simple and stable, but accurate positioning with respect to the connection partner becomes difficult due to manufacturing errors
Solution Approach 1:
The external connection terminal is made movable rather than fixed, allowing it to adjust its position dynamically. The terminal holder enables the external connection terminal to move in multiple directions (X, Y, Z axes) and rotate, transforming a static rigid structure into a dynamic adjustable one that can compensate for manufacturing errors and achieve accurate positioning with the connection partner.
Solution Approach 2:
The positioning capability is extended from a single degree of freedom to multiple degrees of freedom by allowing movement in three spatial dimensions (X, Y, Z axes) and rotation. This multi-dimensional adjustment capability provides sufficient freedom to accommodate manufacturing errors in various directions and achieve precise alignment with the connection partner.
2Manufacturing precision
If the external connection terminal is made movable in multiple directions and rotatable, then positioning accuracy improves, but the device complexity increases
Solution Approach 1:
The terminal holder is designed as a multi-functional component that simultaneously provides support, positioning, and adjustment capabilities. It enables movement in multiple directions and rotation while maintaining a relatively compact and integrated structure, making the complexity acceptable by consolidating multiple functions into a single component.
Solution Approach 2:
The external connection terminal can automatically adjust its own position and orientation through the terminal holder's degrees of freedom, eliminating the need for complex external positioning mechanisms or precise pre-alignment during assembly. The system self-adjusts to compensate for manufacturing errors, reducing the overall complexity of the positioning system.
3Adaptability or versatility
If the external connection terminal is fixed, then the manufacturing process is simple, but it cannot accommodate manufacturing errors in the external connection terminal or connection partner
Solution Approach 1:
The terminal holder transforms the fixed rigid connection into a dynamic adjustable connection, allowing the external connection terminal to adapt its position and orientation to accommodate manufacturing errors in both the terminal and the connection partner, while the manufacturing process remains relatively simple through modular assembly.
Solution Approach 2:
The system allows changes in positional parameters (X, Y, Z coordinates) and orientational parameters (rotation angles) of the external connection terminal to accommodate manufacturing errors. By enabling parameter adjustments rather than requiring precise fixed parameters, the system achieves high adaptability while maintaining ease of manufacture through standard adjustment mechanisms.
Data Source
AI summary
A rotary connector includes a case, a rotor, a flexible cable, an external connection terminal, and a terminal holder. The case includes an outer cylindrical part, the rotor includes an inner cylindrical part, disposed within a housing space of the case, and is rotatably held by the case, the flexible cable is housed in a wound state between the inner cylindrical part and the outer cylindrical part within the housing space, the external connection terminal is provided on an end portion of the flexible cable, and the terminal holder holds the external connection terminal, such that the external connection terminal is movable in a first axis direction and in a second axis direction and is rotatable about a rotation center axis that is parallel to the first axis direction. The first axis direction intersects the second axis direction.