Adjustable Expansion Pin Support Element for Wear-Stable Transfer
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Solution Overview
Problem
Existing support elements for transferring components in high-voltage battery systems, such as module connectors, experience premature wear due to high mechanical stress, leading to unreliable snap-in or clamped connections and requiring frequent replacement, which is complex and costly.
Innovation Solution
A support element with an expansion pin featuring a radially adjustable locking or clamping force, adjusted via an internal adjustment unit, ensures secure mounting by allowing force adjustment through a mechanism involving an adjusting screw, spring, and expansion element, ensuring reliable engagement even under mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the expansion pin is made with fixed locking force, then the initial clamping reliability is ensured, but the locking force decreases over time due to mechanical stress leading to premature wear
Solution Approach 1:
The expansion pin is designed with adjustable shaft segments that can dynamically adapt their radial position. The adjustment unit allows the locking force to be modified during the service life of the support element, transforming a static component into a dynamic one that can compensate for wear and maintain reliable clamping engagement.
2Device complexity
If the expansion pin uses simple fixed geometry, then the device complexity is low, but the ability to adjust locking force decreases leading to frequent replacement
Solution Approach 1:
The pin shaft is divided into multiple radially adjustable shaft segments that can be independently positioned. This segmentation allows the locking force to be adjusted by moving individual segments, providing a relatively simple structural solution that maintains functionality without requiring complete pin replacement.
Solution Approach 2:
The adjustment unit enables operators to readjust the locking force during maintenance intervals without replacing the entire expansion pin. This self-service capability extends the service life and reduces maintenance costs by allowing in-situ adjustment of the shaft segments.
3Loss of substance
If the expansion pin is designed as hollow with internal adjustment unit, then the material usage is reduced and compactness is improved, but the manufacturing complexity increases
Solution Approach 1:
The adjustment unit is nested within the hollow interior of the pin shaft, with the adjusting screw, spring, and shaft segments arranged in a compact nested configuration. This nesting approach reduces material usage and achieves a compact design while concentrating manufacturing complexity in a small internal volume rather than distributing it throughout a larger solid structure.
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
The solution provides a reliable and adjustable locking or clamping force, reducing wear and extending the service life of the support element, thereby simplifying maintenance and reducing costs.
Implementation Method 1
a radially adjustable shaft segment, which can be moved in or out in the radial direction using the adjustment unit to adjust the locking or clamping force
Implementation Method 2
In the locking or clamping engagement, the expansion pin builds up a radially outward-acting locking or clamping force to ensure secure mounting of the component
Data Source
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AI summary
The invention relates to a support element for transferring a component (7) from a placement position (B), in which the support element (15) can be loaded with the component (7), to an assembly position (M), in which the component (7) can be detached from the support element (15) and mounted at a joint. The support element (15) has at least one expanding pin (17) which, after placement, is in a releasable detent or clamp engagement with a component counter contour (33), generating a radially outward-acting detent or clamping force (F). In the assembly position (M), the expanding pin (17) can be disengaged from the detent or clamping engagement with the component counter contour (33). According to the invention, an adjustment unit (39) is associated with the expanding pin (17) by means of which the radially outward-acting detent or clamping force (F) can be adjusted.