Break-away Tractor-Trailer Connector Segmentation
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Solution Overview
Problem
Existing tractor-trailer electrical connectors often fail to break away without damage when the tractor pulls away from a parked trailer, and their terminal connection systems cause voltage drops, especially in long trailer configurations, due to added connection points that increase voltage loss over time.
Innovation Solution
A connector assembly with a housing and a releasable connector body, where terminal pins are secured to the housing, allowing the connector body to break away without damaging the terminals, thus eliminating additional connection points and reducing voltage drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cap locking mechanism is used to secure the trailer electrical cable to the connector, then the connector can resist inadvertent disconnects, but the locking mechanism may fail to release when the vehicle pulls away, causing damage to the connector mounting
Solution Approach 1:
The connector is divided into two separate parts: a stationary housing mounted to the cab that contains the terminal pins, and a movable connector body that receives the trailer cable plug. The locking tabs are attached to the stationary housing, while the rib is attached to the movable connector body. This segmentation allows the connector body to break away from the housing without damaging the terminal pins or mounting, as the terminal pins remain secured to the stationary housing while the connector body detaches cleanly.
2Reliability
If a terminal connection system with additional connection points is used to connect the connector to the tractor wiring harness, then the connector can provide electrical connection, but the additional connection points cause voltage drop that increases over time
Solution Approach 1:
The terminal pins are extracted from the movable connector body and permanently secured to the stationary housing. This eliminates the need for additional connection points between the connector body and housing, as the terminal pins provide a permanent, direct electrical connection from the housing to the connector body. By removing the intermediate connection points that would otherwise be required, the invention reduces voltage drop and eliminates the progressive degradation associated with multiple connection interfaces.
3Device complexity
If the connector is designed as a single integrated unit, then the structure is simpler, but the entire connector including terminals may be damaged during breakaway events
Solution Approach 1:
The connector is segmented into a stationary housing containing the terminal pins and a movable connector body with the cable plug reception. The locking tabs on the housing engage with the rib on the connector body to provide secure connection during normal use, but allow clean separation during breakaway. This segmentation protects the terminal pins by keeping them permanently mounted to the stationary housing, while the connector body can safely detach without causing damage to the overall system.
Data Source
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AI summary
An electrical connector for connecting a tractor-trailer electrical cable to a truck tractor or a trailer electrical system includes a housing defining an interior space and having a mounting flange extending radially therefrom at a head end, at least one locking tab at the head end, and a wall dividing the interior space into a head end space and a foot end space, the wall having a plurality of holes in an array, a plurality of terminal pins secured against movement in the holes in the wall and extending from the foot end space into the head end space and a connector body having an outer wall configured to slide into the head end space of the housing, the connector body defining an interior socket space configured to receive a plug of an electrical cable, the connector body having a terminal support wall at a foot end of the connector body, the terminal support wall having an equal plurality of holes in the array to receive the plurality of terminal pins, and having an external circumferential rib at a head end. The connector body is insertable in the head end space of the housing to a position with the terminal pins extending through the holes in the terminal support wall into the socket space and the at least one locking tab engaging the circumferential rib to secure the connector body in the housing.