Wire Harness Connector Assembly for Versatile Terminal Welding
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Solution Overview
Problem
Existing wire harness manufacturing methods require dedicated connectors for male and female terminals, limiting versatility and necessitating separate installation, which increases costs and reduces flexibility.
Innovation Solution
A method involving accommodating terminals in housings with specific grooves, welding exposed core wires to terminal connection portions, and assembling covers to form connectors, utilizing laser welding for versatility and compatibility with mass production connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated connectors for male and female terminals are used, then reliable electrical connection is achieved, but versatility of the connector and terminal is limited and component costs increase
Solution Approach 1:
The patent applies universality by designing a single connector structure that can accommodate both male terminals and female terminals. The connector housing includes terminal accommodation grooves that can receive different terminal types, and the insulating housing with conductive metal plates provides a unified structure for various electrical connections, eliminating the need for separate dedicated connectors for male and female terminals.
2Reliability
If dedicated connectors for male and female terminals are used, then reliable electrical connection is achieved, but component costs increase due to separate installation requirements
Solution Approach 1:
The patent merges the functions of separate male and female terminal connectors into a single unified connector structure. The insulating housing integrates multiple terminal accommodation grooves, and the conductive metal plates are embedded within the same housing structure, allowing both male and female terminals to be connected through one connector assembly rather than requiring separate connectors for each terminal type.
3Manufacturing precision
If laser welding is used to weld conductive metal plate and electric wire, then welding precision and automation are improved, but the connector becomes dedicated to laser welding process
Solution Approach 1:
The patent applies universality by designing the connector structure to be process-agnostic. The insulating housing with embedded conductive metal plates and terminal accommodation grooves creates a universal connector body that can accommodate different terminal types and connection methods. The structure itself does not depend on the welding process, allowing the same connector design to be used whether laser welding, crimping, or other connection methods are employed.
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
Enhances connector and terminal versatility, reduces component costs, and allows easy conversion between laser welding and crimp terminals, while maintaining protection and ease of assembly.
Implementation Method 1
the core wire exposed portion is brought into contact with an electric wire connection portion of the terminal and welded
Data Source
AI summary
A wire harness manufacturing method includes a first welding step in which an electric wire connection portion of a first terminal accommodated in a first terminal accommodation groove and a core wire exposed portion are welded, a second welding step in which the electric wire connection portion of a second terminal accommodated in a second terminal accommodation groove and the core wire exposed portion are welded, a first cover assembling step in which a first cover is assembled to a first housing, and a second cover assembling step in which a second cover is assembled to a second housing so as to close the second terminal accommodation groove. Thereafter, in a connector forming step, the first housing and the second housing are stacked and assembled to each other in a height direction to form a connector to be fitted to a mating connector.