Blind Connector Alignment for Large Misalignment Compensation
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Solution Overview
Problem
Existing blind connection systems in electrical connectors fail to compensate for large misalignments along both perpendicular and insertion directions, limiting their effectiveness in automated assembly processes.
Innovation Solution
A method and system that utilize slanted surfaces and elastic means to automatically align connectors, allowing for coaxial alignment along perpendicular directions and compensation for non-parallelism along the insertion direction, enabling secure and stable electrical connections despite significant misalignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If blind connection systems are used for automated assembly, then productivity is improved, but the system cannot compensate for large misalignments along perpendicular directions
Solution Approach 1:
The patent employs a movable connector component that can dynamically adjust its position along the insertion direction to compensate for misalignments. The connector includes a movable body that shifts relative to the fixed body, enabling the system to adapt to position variations while maintaining automated assembly capabilities
Solution Approach 2:
The patent changes the positional parameter of the connector components by introducing a movable body that can translate along the insertion direction. This parameter change allows the system to compensate for misalignments up to ±4 mm while preserving automated assembly productivity
2Ease of operation
If blind connection systems are used for automated assembly, then ease of operation is improved, but the system cannot compensate for misalignments along the insertion direction
Solution Approach 1:
The movable connector body dynamically adjusts its position along the insertion direction to compensate for misalignments, ensuring reliable electrical contact while maintaining ease of automated operation. The dynamic adjustment mechanism allows the system to self-correct position errors without human intervention
Solution Approach 2:
The connector system performs self-alignment through the movable body that automatically compensates for misalignments during the insertion process. This self-service mechanism ensures connection reliability while maintaining automated operation without requiring external adjustment devices
3Manufacturing precision
If slanted surfaces are used for alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent uses a dynamic movable body instead of complex fixed alignment structures. The slanted surfaces guide the initial engagement, but the movable body completes the alignment process through controlled movement, achieving coaxial alignment with simpler overall device architecture
Solution Approach 2:
The movable body acts as an intermediary element between the slanted surfaces and the final coaxial alignment. It receives the guidance from the slanted surfaces and translates this into precise positioning, reducing the complexity of the alignment mechanism while maintaining manufacturing precision
4Adaptability or versatility
If elastic means are added for compensation, then adaptability is improved, but device complexity increases
Solution Approach 1:
The elastic means enable the connector body to dynamically adjust its position in response to misalignments. The elastic deformation provides adaptive compensation for position variations while maintaining a relatively simple system structure compared to rigid adjustment mechanisms
Solution Approach 2:
The elastic means change the positional parameter of the connector body through elastic deformation. This allows the system to adapt to various misalignment conditions while using a simple elastic element rather than a complex adjustment mechanism, improving adaptability without significantly increasing device complexity
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
Enables reliable and automated electrical connections by compensating for misalignments up to ±4 mm in both perpendicular and insertion directions, ensuring secure contact between connectors without human intervention.
Implementation Method 1
a plurality of elastic means configured to apply a compensation force on the main second connector so as to align them and make them parallel to each other
Implementation Method 2
Positioning the main second connector in such a way that at least one portion of the second slanted surface contacts at least one portion of the first slanted surface; Inserting the main second connector in the main first connector along an insertion direction, whereby a first force on the main second connector is created
Data Source
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AI summary
The present invention refers to a method for making a blind connection between a main first and a main second connector, wherein, thanks to the particular geometry of the main first and second connectors, a displacement of the main second connector is induced and coarse coaxial alignment with the main first connector is obtained. This method allows correction of large misalignments between the two connectors, because displacement and alignment of the main second connector are already guided during approaching of the two connectors. The present invention also refers to a method for making a blind connection between a main first and second connector, wherein the positions of the two connectors can be automatically adjusted so as to make them parallel to each other. The present invention finally refers to the corresponding blind connection systems.