Single-Axis Connector Assembly for Lower Precision Insertion
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Solution Overview
Problem
Conventional connectors require high precision in assembly and manufacturing due to the need for precise alignment along multiple axes, leading to increased complexity and cost.
Innovation Solution
A connector design where the housing, terminal, and cover are assembled along a single axis, eliminating the need for high-precision alignment and independent electrical connections between mating terminals, simplifying the assembly process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two mating terminals are electrically connected within one connection part, then electrical connection is achieved, but manufacturing precision and assembly precision requirements increase significantly
Solution Approach 1:
The terminal is divided into separate first connection part and second connection part, each independently receiving and electrically connecting with respective mating terminals. This segmentation eliminates the need for high-precision simultaneous insertion of two terminals into a single connection part, while maintaining reliable electrical connections through distributed contact points.
2Stability of the object's composition
If housing and cover are assembled along axes orthogonal to the assembly axis of housing and terminal, then proper positioning is achieved, but assembly complexity and automation difficulty increase
Solution Approach 1:
The housing, terminal, and cover are all configured to assemble along the same first axis. This merging of assembly axes simplifies the overall assembly process, enabling linear sequential assembly of all components along a single direction, which facilitates automation while maintaining proper positioning through aligned feature geometry.
Data Source
AI summary
A connector includes a housing, a terminal configured to be assembled to the housing, and a cover configured to be assembled to the housing. The terminal has a first connection part configured to be electrically connected to a first mating terminal, and a second connection part configured to be electrically connected to a second mating terminal. The housing, the terminal, and the cover are formed to be assembled along a first axis.