Socket With Embedded Nut And Elastic Tabs For Wire Harness Terminal
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Solution Overview
Problem
Conventional methods for pre-fixing three phase connection lines in high-voltage junction boxes for electric vehicles are complex, inefficient, and labor-intensive, affecting production pace and increasing costs.
Innovation Solution
A connection structure and method using a socket with an embedded nut featuring elastic tabs that deform to clamp a wire harness terminal, allowing for simple and accurate positioning, and a screw for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional pre-fixing processes are used for wire harness terminals, then connection can be achieved, but the process becomes complicated and labor costs increase
Solution Approach 1:
The fixing mechanism is segmented into modular components: a socket with an embedded nut and elastic tabs, separate from the wire harness terminal. This allows the socket to be pre-assembled with the elastic tab mechanism, simplifying the overall assembly process and reducing operational complexity while maintaining ease of manufacture.
Solution Approach 2:
The elastic tabs are designed to automatically deform and clamp the wire harness terminal when inserted into the socket. This self-clamping mechanism eliminates the need for additional fixing tools or complex manual operations, reducing labor costs and simplifying the pre-fixing process while ensuring reliable connection.
2Productivity
If conventional pre-fixing methods are used, then wire harness terminal can be fixed, but production efficiency decreases and labor costs increase
Solution Approach 1:
The socket is pre-assembled with the nut and elastic tabs before the wire harness terminal is inserted. This preliminary preparation of the socket allows for rapid insertion and clamping of the terminal, significantly reducing pre-fixing time and increasing production efficiency without requiring additional assembly steps during the main assembly process.
Solution Approach 2:
The elastic tabs automatically deform and clamp the wire harness terminal upon insertion, creating a self-fixing mechanism that eliminates time-consuming manual fastening operations. This self-service clamping action dramatically reduces pre-fixing time and enhances overall productivity.
3Manufacturing precision
If elastic tabs are used to clamp wire harness terminal, then positioning accuracy improves, but risk of damaging other parts increases
Solution Approach 1:
The elastic tabs are designed with specific material properties and geometric parameters that allow them to deform elastically within a controlled range. By optimizing the elasticity parameter and clamping force, the system achieves accurate positioning of the wire harness terminal while maintaining clamping force below the damage threshold for surrounding components.
Solution Approach 2:
The elastic tabs concentrate the clamping force locally at the contact point with the wire harness terminal, ensuring precise positioning without distributing excessive force to other parts. The local deformation of the elastic tabs provides the necessary holding force while protecting surrounding components from damage through controlled stress concentration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies the pre-fixing process, reduces manufacturing costs, and ensures accurate positioning while avoiding damage to other components, enhancing production efficiency.
Implementation Method 1
a pair of elastic tabs protrudes from two sides of an upper end surface of the nut, and the elastic tabs are deformable so as to pre-fix the wire harness terminal on the socket
Data Source
Figure 1~2
Figure 3
AI summary
The present disclosure discloses a connection structure and method of a wire harness terminal (4) and a socket (1). In the connection structure, a nut (3) is embedded in an upper surface of the socket (1), a threaded hole (2) is provided in the nut (3) in an axial direction of the nut (3), and a pair of elastic tabs (5) protrude from two sides of an upper end surface of the nut (3), and the elastic tabs (5) are deformable so as to pre-fix the wire harness terminal (4) on the socket (1). The structure for pre-fixing the wire harness terminal (4) on the socket (1) disclosed in the above technical solution is simple in structure, low in manufacturing cost, convenient to operate, accurate in positioning, and can avoid damage to other parts.