Integrated Bridge Element for Transmission Actuator Connections
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Solution Overview
Problem
Existing solutions for establishing electrical and mechanical connections between actuators and electronic circuit arrangements in transmission control units are inefficient, as they often require multiple contact points and lack effective sealing against dirt and metal chips, leading to potential short circuits.
Innovation Solution
A bridge element with dual plug functionality, featuring electrical conductors and mechanical connecting elements that allow simultaneous electrical and mechanical connection, utilizing spring pressure contacts, knife/fork contacts, or pin/hole plug contacts, and incorporating a labyrinth sealing mechanism to prevent conductive particle penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple contact points are used for electrical connection, then electrical connectivity is improved, but device complexity and risk of short circuits increase
Solution Approach 1:
The patent combines multiple electrical contacts and mechanical connection elements into a single integrated bridge element. This single component establishes both electrical and mechanical connections between the actuator and electronic circuit arrangement, reducing the number of separate contact points while maintaining reliable electrical connectivity.
Solution Approach 2:
The bridge element is designed as a multi-functional component that simultaneously provides electrical contact, mechanical support, and sealing functions. This universal design eliminates the need for separate dedicated contact points, reducing overall device complexity while ensuring reliable electrical connection.
2Object-affected harmful factors
If traditional connection methods are used, then assembly is simple, but sealing against dirt and metal chips is insufficient
Solution Approach 1:
The sealing function is merged with the connection element itself. The bridge element incorporates sealing features that work together with the mechanical connection to prevent contaminant ingress, eliminating the need for separate sealing components while maintaining effective protection against dirt and metal chips.
Solution Approach 2:
The bridge element acts as an intermediary component between the actuator and electronic circuit arrangement, providing a sealed pathway for electrical connection. This intermediate structure prevents direct exposure of electrical contacts to contaminants while maintaining electrical connectivity.
3Reliability
If separate mechanical and electrical connections are used, then connection reliability is improved, but assembly time and process complexity increase
Solution Approach 1:
The patent merges mechanical connection and electrical contact functions into a single integrated bridge element. This allows both mechanical support and electrical connectivity to be established simultaneously in one assembly operation, reducing assembly time while maintaining the reliability benefits of both connection types.
Solution Approach 2:
The bridge element is pre-designed and pre-assembled with both mechanical and electrical features integrated. This preliminary preparation allows for rapid installation as a single unit, eliminating the need for sequential assembly operations while ensuring both mechanical and electrical connections are properly established.
Data Source
AI summary
A bridge element (3) for establishing an electrical connection and at least one mechanical connection between an actuator (1) and a bridge element (3) for a transmission control unit of a transmission includes first electrical contacts (5a, 6a) and second electrical contacts (5b, 6b), which are connected to the first electrical contacts (5a, 6a) with electrical conductors (5, 6), and at least first mechanical connecting elements (7, 8) proximate the first electrical contacts (5a, 6a).