Electro-thermal Actuator Multipolar Connector Coding
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Solution Overview
Problem
Existing electro-thermal actuator devices face issues with unreliable electrical connections, especially in harsh conditions, and risk of accidental contacts or erroneous wiring due to exposed faston connectors, which can lead to safety hazards and operational failures.
Innovation Solution
The electro-thermal actuator device incorporates a specific multipolar connector with coding means and secure engagement elements, transforming traditional faston connectors into a Rast 2.5 type connector with unique insertion keys to prevent accidental connections and ensure reliable electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional faston connectors are used for electrical connection, then the connection process is simple and quick, but the connection reliability deteriorates under high vibrations and thermal stresses
Solution Approach 1:
The electrical connection system is segmented into modular components: a connector integrated into the actuator housing and a separate plug connected to the power supply cable. This segmentation allows each component to be optimized independently - the connector provides stable mechanical anchoring while the plug ensures reliable electrical contact, resolving the contradiction between ease of connection and connection reliability under vibration and thermal stress
Solution Approach 2:
The connector is nested within the actuator housing structure, with the power supply cable plug inserted into the connector. This nesting arrangement protects the electrical connection from external vibrations and thermal stresses while maintaining a compact, integrated design that does not complicate the connection process
2Ease of operation
If male faston terminals are exposed outside the actuator device, then the connection is accessible, but the risk of accidental contact and electrocution increases
Solution Approach 1:
The exposed male faston terminals are extracted from the external environment and repositioned inside the actuator housing. The electrical connection points are now located within the protected interior of the housing, eliminating direct exposure to the external environment where accidental contact could occur, while the connector design maintains accessibility for intentional connection operations
Solution Approach 2:
The actuator housing acts as a protective shell enclosing the electrical connection components. This housing provides physical isolation between the electrical terminals and the external environment, preventing accidental contact while maintaining a compact design that does not significantly increase the device footprint
3Adaptability or versatility
If single faston connectors are used, then the device can be connected to various apparatuses, but the risk of erroneous wiring and short circuits increases
Solution Approach 1:
The connector incorporates asymmetric coding features such as positioned protrusions and corresponding recesses that create a unique geometric configuration. This asymmetry prevents mismatched connectors from being physically inserted, eliminating the risk of erroneous wiring and short circuits while maintaining adaptability through standardized connector types that can be paired with corresponding plugs across different apparatuses
Solution Approach 2:
The connector serves as an intermediary element between the actuator and the power supply cable, incorporating coding and keying features that mediate the connection process. This intermediary ensures compatibility through standardized interfaces while preventing incorrect connections through geometric coding, thus maintaining versatility without compromising electrical system reliability
4Ease of manufacture
If different types of actuators are produced with same connectors, then production is simplified, but the risk of mounting wrong actuator type increases
Solution Approach 1:
While maintaining a standardized connector design for uniformity across different actuator types, local quality variations are introduced through coding features such as differently positioned protrusions, varying numbers of contact pins, or specific geometric configurations. These localized differences enable differentiation between actuator types without requiring complete redesign of the connector, thus maintaining production simplicity while preventing incorrect mounting
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 solution enhances the reliability and safety of electrical connections, preventing erroneous wiring and accidental contacts, while allowing for easier and quicker connection processes, thereby reducing the risk of operational failures and safety hazards.
Implementation Method 1
The actuator in turn comprises a body made of electrically and thermally conductive material (e.g. steel), containing a temperature-expandable material, such as a wax, into which is at least partially immersed a piston... said body is in contact with an electrical heater, usually a PTC resistor
Implementation Method 2
containing a temperature-expandable material, such as a wax... the wax, into which is at least partially immersed a piston, destined to drive the actuating shaft
Data Source
AI summary
An electro-thermal actuator device comprises a case defining a cavity in which are housed a thermal actuator, an electrical heater and, at least partially, an actuating shaft. The device comprises a multipolar connector for the rapid, secure and reliable coupling to a respective source of electrical power supply for the heater. The connector can be configured as an adapter unit distinct from the case, suitable to transform a traditional electro-thermal actuator device into a device according to the invention.