Wire Terminal Connector Structure for Confined-Space Assembly
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Solution Overview
Problem
The existing connectors for electric wires in confined spaces, such as within box-shaped bodies like vehicle transmissions, face difficulties in workability due to the elastic force of curved wires, especially with thick wires or large curvature, making connection challenging in narrow internal spaces.
Innovation Solution
A connector design featuring a housing with bus bars and nuts that allow the terminal fitting to be temporarily fixed in a gap between the fastened portion and the nut, utilizing the elastic force of the wire for frictional holding, facilitating easier assembly without requiring precise alignment or continuous pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal fitting is connected directly to the bus bar in a narrow internal space, then the connection is secure, but the workability deteriorates due to the elastic force of curved electric wires making it difficult to perform connection work
Solution Approach 1:
The connection structure is segmented into three distinct components: the bus bar body portion, the fastened portion, and the nut. This segmentation allows the terminal fitting to be temporarily positioned in the gap between the fastened portion and nut before final fastening, reducing the operational burden during connection work while maintaining secure connection through the bolt-nut fastening system
Solution Approach 2:
The gap between the fastened portion and nut acts as an intermediary space that temporarily holds the terminal fitting. This intermediary structure allows the terminal fitting to be positioned and held in place by the elastic force of the curved electric wire before the bolt is fully fastened, improving workability without compromising connection reliability
2Volume of moving object
If the electric wire is curved with a small radius of curvature to fit the narrow internal space, then the wire can be routed, but the elastic force increases making connection work more difficult
Solution Approach 1:
The elastic force generated by the curved electric wire, which would normally hinder connection work, is utilized beneficially to hold the terminal fitting in the gap between the fastened portion and nut. The wire's own elastic force serves the dual purpose of maintaining its curved shape for space utilization and facilitating easier connection work by temporarily securing the terminal fitting
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 the workability of connecting terminal-equipped electric wires by allowing temporary fixation and easier fastening, reducing the operational burden and improving the reliability of connections within confined spaces.
Implementation Method 1
the elastic force generated by the curved electric wire (41), and thus it is further difficult to perform the connection work inside the box-shaped body
Data Source
AI summary
A connector includes a housing to be assembled to a wall portion of a box-shaped body, a bus bar having a fastened portion disposed inside the wall portion and is to be connected to a terminal fitting by fastening using a bolt, and a nut held by the housing with a gap between the nut and the fastened portion into which the terminal fitting is capable of being inserted and engaged with the bolt to fasten the fastened portion and the terminal fitting inserted into the gap together.