Round Terminal Securing Structure Against Harness Repulsive Force
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Solution Overview
Problem
The repulsive force exerted by thicker harnesses in power supply devices can cause round terminals to rotate or displace, leading to inefficient assembly and potential disconnection, especially in high-capacity devices with limited space, where the repulsive force is more pronounced.
Innovation Solution
A power supply device with guide pieces and optional guide pins that hold the round terminal in place, preventing rotation and displacement by securing it to a housing with screws, and optionally using positioning pins to further stabilize the terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the harness is made thicker to achieve higher output and capacity, then the power supply capability is improved, but the repulsive force increases causing the round terminal to rotate or displace
Solution Approach 1:
The guide piece is designed to preemptively counteract the repulsive force effect on the round terminal. By providing a guiding surface that contacts the round terminal before the repulsive force can cause rotation or displacement, the guide piece prevents the harmful effect from occurring in the first place, allowing the harness to be thicker for higher power without compromising terminal stability
2Power
If the number of battery cells is increased to achieve higher output, then the power supply capability is improved, but the harness becomes thicker and less flexible increasing repulsive force
Solution Approach 1:
The guide piece provides preliminary counteraction to the repulsive force generated by the thicker, less flexible harness. The guiding surface ensures the round terminal maintains proper orientation and position despite the increased stiffness and repulsive force from the thicker harness required for higher output capacity
3Volume of moving object
If the power supply device is made more compact to save space, then the device size is reduced, but the wiring routing is more constrained increasing repulsive force on the round terminal
Solution Approach 1:
The guide piece preemptively counteracts the repulsive force effect that arises from constrained wiring routing in compact devices. By providing a guiding surface that contacts the round terminal, it prevents rotation and displacement caused by the harness being forced through tight spaces, maintaining terminal stability despite the compact form factor
4Ease of manufacture
If standing pieces are used to position the round terminal, then the terminal positioning is simplified, but the contact area is small resulting in low frictional resistance and allowing rotation under repulsive force
Solution Approach 1:
The guide piece features a guiding surface with specific local properties - a larger contact area with higher frictional resistance compared to conventional standing pieces. This localized improvement in contact quality at the guide piece-round terminal interface provides sufficient friction to prevent rotation while maintaining ease of assembly
Solution Approach 2:
The guide piece transitions from the simple vertical support of standing pieces to a surface-based constraint system. The guiding surface provides constraint in multiple directions (preventing rotation and displacement) rather than just vertical support, adding dimensional control without significantly increasing complexity
Data Source
AI summary
A power supply device includes: a battery cell; a harness connected to the battery cell; a round terminal connected to the harness; a circuit board electrically connected to the round terminal; a housing accommodating the battery cell, the circuit board, the harness, and the round terminal therein; and a pair of guide pieces holding the round terminal. The round terminal includes a flat part including an end portion having a terminal screw hole passing through the flat part in up and down directions, and a crimp part crimped together with an end of the harness so as to be connected to the end of the harness. The pair of guide pieces respectively holds edges of the flat part of the round terminal in right and left directions perpendicular to the up and down directions while the round terminal is fixed to the housing with a screw inserted into the terminal screw hole.