Terminal Assembly Insertion Coupling Eliminates Welding
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Solution Overview
Problem
Conventional power supply terminals in motor assemblies require welding for connection, which hinders automation and alignment accuracy, leading to potential separation issues.
Innovation Solution
A terminal assembly with a power supply terminal module featuring a bent insertion part and support part for easy alignment, coupled with a bus bar terminal module using an insertion coupling method, incorporating a fixture hanging pattern for secure fixation and preventing separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding process is used to connect power supply terminal and bus bar terminal, then electrical connection is achieved, but automation is hindered and alignment accuracy deteriorates
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical insertion coupling system. The power supply terminal is inserted into the bus bar terminal through a guide groove and fixed by a hanging pattern, eliminating the need for welding equipment and processes, thereby enabling full automation while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces a guide groove and hanging pattern as intermediary structures between the power supply terminal and bus bar terminal. These intermediaries facilitate precise alignment and secure mechanical coupling, replacing the direct welding connection with an intermediate mechanical coupling system that enables automation.
2Reliability
If welding process is used to connect power supply terminal and bus bar terminal, then electrical connection is achieved, but alignment accuracy at mounting points deteriorates
Solution Approach 1:
The patent incorporates a guide groove structure in advance within the bus bar terminal, which preliminarily guides and positions the power supply terminal during insertion. This preliminary alignment action ensures accurate mounting alignment before the final coupling is established, eliminating alignment errors that would occur with welding processes.
Solution Approach 2:
The guide groove acts as an intermediary alignment mechanism that ensures precise positioning of the power supply terminal relative to the bus bar terminal. This intermediary structure maintains high manufacturing precision by providing a defined insertion path and contact surfaces for accurate alignment.
3Extent of automation
If insertion coupling method is used instead of welding, then automation is enabled and alignment accuracy is improved, but connection strength may deteriorate
Solution Approach 1:
The coupling system is segmented into multiple functional components: the guide groove for alignment, the hanging pattern for mechanical interlocking, and the contact surfaces for electrical connection. This segmentation allows each component to be optimized for its specific function, with the hanging pattern providing sufficient mechanical strength while enabling automation.
Solution Approach 2:
The coupling system employs composite structural design combining conductive materials for electrical connection with mechanically strong materials for the hanging pattern and guide groove. This composite approach ensures both high connection strength and electrical conductivity while maintaining automation compatibility.
4Productivity
If insertion coupling method is used instead of welding, then manufacturing efficiency is enhanced, but separation resistance may deteriorate
Solution Approach 1:
The hanging pattern is designed with a dynamic interlocking mechanism that provides strong resistance to separation forces. The pattern allows for easy insertion (facilitating high productivity) while creating a mechanical lock that resists pull-out forces (ensuring high separation resistance and reliability).
Solution Approach 2:
The hanging pattern incorporates curved or angled surfaces that provide mechanical interlocking resistance to separation. The geometric configuration of the hanging pattern creates friction and mechanical engagement that prevents separation while allowing straightforward insertion during automated assembly.
Data Source
AI summary
The present embodiment relates to a terminal assembly comprising: a power supply terminal module, which comprises a power supply terminal and a support part, the power supply terminal including a body part and an insertion part bent and extended from an end of the body part and the support part being coupled to the power supply terminal so as for the body part to penetrate therethrough; and a bus bar terminal module, which comprises a bus bar guide groove, in which the insertion part is inserted, and a bus bar terminal, which is placed in the bus bar guide groove and is in contact with the insertion part.