Self-locking Axial Electrical Connector Mechanism
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Solution Overview
Problem
Existing electrical connectors in aeronautical and military applications face challenges with secure mechanical coupling, as they require manual torque measurement tools, leading to inefficiencies in assembly and maintenance due to the need for precise torque tightening and potential loss of tools, which can result in accidental disconnections and increased time and economic costs.
Innovation Solution
A self-locking mechanism for electrical connectors with axial coupling, utilizing a pusher guided by radial studs and a torsion spring, allowing for one-handed assembly and disassembly without the need for tools, ensuring secure locking through a bayonet-type connection and elastic elements that deform to provide pre-holding and locking functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual torque measurement tools are used to tighten connectors, then connection security is improved, but assembly time increases and tool loss risk increases
Solution Approach 1:
The connector incorporates a self-locking mechanism with elastic elements that automatically engage when the connector is assembled, eliminating the need for external torque measurement tools. The elastic elements deform during assembly to provide automatic locking, making the system self-servicing and removing dependency on manual intervention with specialized tools.
Solution Approach 2:
The patent replaces the mechanical torque measurement and tightening system with an elastic deformation-based self-locking mechanism. Instead of using torque wrenches and sockets to achieve secure connections, the system uses elastic elements that deform during assembly to create automatic mechanical locking, substituting complex mechanical tooling with a simpler elastic mechanism.
2Manufacturing precision
If torque wrenches and sockets are used for tightening, then precise torque control is achieved, but tool loss and damage risk increases
Solution Approach 1:
The connector design eliminates the need for external torque wrenches and sockets by incorporating self-locking elastic elements that automatically control the tightening force during assembly. The system serves itself by using the deformation characteristics of the elastic elements to achieve precise torque control without requiring separate precision tools.
Solution Approach 2:
The patent extracts and eliminates the torque wrench and socket tools from the assembly process entirely. By removing these external tools and replacing them with integrated elastic locking elements, the system eliminates the harmful factors associated with tool loss and damage while maintaining precise torque control through the elastic deformation mechanism.
3Reliability
If conventional screw-fixing or clip-on connectors are used, then connection security is achieved, but checking connection condition becomes difficult and time-consuming
Solution Approach 1:
The patent incorporates visual indicators that change appearance based on the connection state. The design includes features that allow operators to quickly assess connection conditions through visual inspection, such as color-coded indicators or visible positional changes of connection elements, making it easy to verify connection security without time-consuming manual checks.
4Productivity
If quarter-turn locking systems are used, then assembly speed is improved, but locking may be partially achieved without being apparent
Solution Approach 1:
The patent incorporates visual indicators that provide immediate feedback on locking completion. The design includes visible markers or color-coded elements that change position or appearance when full locking is achieved, allowing operators to quickly verify that the quarter-turn locking system has completed the full rotation and achieved proper engagement, eliminating uncertainty about locking status.
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 significantly reduces assembly time and improves working comfort by eliminating the need for manual torque measurement tools, ensuring secure connections and reducing the risk of accidental disconnections, while being easily integrated into existing connectors with minimal economic impact.
Implementation Method 1
A self-locking mechanism for electrical connectors with axial coupling, utilizing a pusher guided by radial studs and a torsion spring
Implementation Method 2
elastic elements that deform to provide pre-holding and locking functions
Data Source
Figure 1~5
Figure 6~7
AI summary
The invention relates to a locking fastening device for two-part electrical connectors (1, 2) with axial coupling, comprising two male keying elements (4) and two female keying elements (3) included in said parts (1, 2), said keying elements (3, 4) being arranged on either side of the contacts of the two parts (1, 2) of the male (2) and female (1) electrical connector and comprising respectively at least one protrusion (41) and one bore (33) capable of cooperating axially to achieve the fastening of the parts (1, 2) during coupling.