Terminal Metal Fitting Springback Compensation Segmentation
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Solution Overview
Problem
Conventional terminal metal fittings face challenges in productivity due to springback, which causes deformation and makes it difficult to correctly fit piece parts into grooves during the bending process, leading to gaps that are hard to manage accurately.
Innovation Solution
The terminal metal fitting incorporates first and second engaging parts with gaps that allow movement opposite to the separating directions due to springback, enabling easy insertion of the first engaging part into a notch, thus preventing outward deformation without requiring enhanced processing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a piece part is fitted into a groove to prevent outward deformation due to springback, then the terminal connecting body is prevented from deforming, but the gap between the piece part and groove is very small making it difficult to correctly fit during bending
Solution Approach 1:
The terminal connecting body is divided into multiple engagement parts: a first engagement part (piece part) and a second engagement part (groove with engagement protrusion), along with a third engagement part. This segmentation allows the deformation prevention function to be distributed across multiple interaction points, enabling easier fitting while maintaining reliability.
Solution Approach 2:
The second engagement part acts as an intermediary between the first and third engagement parts. The groove with engagement protrusion provides a intermediate structure that guides and facilitates the fitting of the piece part, making the overall engagement process more accurate and easier to perform during bending.
2Manufacturing precision
If enhanced processing accuracy is required to correctly fit piece parts into grooves, then fitting accuracy improves, but productivity decreases
Solution Approach 1:
By segmenting the engagement structure into multiple parts with distributed functions, the fitting process becomes more tolerant to variations in bending accuracy. The first, second, and third engagement parts work together to achieve reliable deformation prevention without requiring extremely tight tolerances, thereby maintaining high productivity.
Solution Approach 2:
The invention changes the geometric parameters of the engagement structures, specifically designing the groove with an engagement protrusion and positioning it at a specific location. This parameter optimization allows for easier fitting while maintaining accurate shape formation, resolving the trade-off between precision and productivity.
3Stability of the object's composition
If the gap between engaging parts is made very small to prevent deformation, then outward deformation is prevented, but it becomes difficult to correctly fit the piece part into the groove during bending
Solution Approach 1:
The engagement system is segmented into multiple parts that work together: the first engagement part provides deformation resistance, the second engagement part (groove with protrusion) provides guidance and positioning, and the third engagement part provides additional stability. This segmentation allows for larger, more manageable gaps while maintaining shape stability.
Solution Approach 2:
The invention introduces a dimensional aspect to the engagement structure by creating a groove with an engagement protrusion that extends in a specific direction. This dimensional feature provides additional degrees of freedom for fitting, making the engagement process easier while maintaining stability against outward deformation.
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
This design enhances productivity by allowing easy engagement of the first and second engaging parts, preventing outward deformation caused by springback while maintaining accurate shape formation, even with slight deviations in the bending process.
Implementation Method 1
Springback occurs in such a terminal connecting body that is obtained by performing the bending process. The springback is a tendency to return to the developed shape.
Data Source
AI summary
A terminal connecting body of a terminal metal fitting includes: a first engaging part and a second engaging part on one end side and another end side, respectively, that engage each other movements of an end of the one end side and an end of the other end side in separating directions; has a first gap formed between the first engaging part and the end of the other end side, that allows the end and the other end in directions opposite to the separating directions; and has a second gap formed therein, between the second engaging part and the end of the one end side, that enables the end and the other end in similar opposite directions. The first gap and the second gap are formed so that the first engaging part can be inserted into a notch provided on the other end side while being bent from its base.