Cable Connector Plug Count Limiter for Wear-Out Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cable connectors lack a reliable mechanism to count the number of plug-in events and prevent further usage after reaching a threshold, leading to unexpected failures and downtime due to mechanical wear and degradation.
Innovation Solution
A cable connector design featuring an outer sleeve, inner sleeve, gear wheel, toggle plug counter, and inner spring, which counts plug-in events and prevents further plugging by aligning a tab on the inner sleeve with a notch on the gear wheel, triggering the inner spring to move the inner sleeve into a blocking position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cable connectors are designed to allow frequent plugging and unplugging, then ease of operation is improved, but reliability deteriorates due to mechanical wear and degradation
Solution Approach 1:
The connector performs preliminary counting of plug-in events and disables itself before actual failure occurs. The counter mechanism tracks usage and prevents further operation when a threshold is reached, proactively avoiding the reliability degradation that would result from continued use beyond the connector's lifespan.
2Device complexity
If no plug-in event counting mechanism is implemented, then device complexity is reduced, but reliability deteriorates due to unexpected failures
Solution Approach 1:
A gear wheel acts as an intermediary mechanical component that translates the linear motion of repeated plugging events into rotational motion, incrementing a counter. This mechanical intermediary enables reliable counting and threshold detection without requiring complex electronic sensors or control systems, maintaining simplicity while improving reliability.
3Reliability
If a mechanical counter mechanism is added to track plug-in events, then reliability is improved by preventing overuse, but device complexity increases
Solution Approach 1:
The connector performs self-monitoring and self-disabled through the mechanical counter mechanism. Each plug-in event automatically increments the counter, and when the threshold is reached, the connector automatically disables itself without requiring external monitoring or control systems. This self-service approach improves reliability while minimizing the addition of complex external components.
Solution Approach 2:
The patent replaces potential electronic counting and control systems with a purely mechanical counter mechanism using gear wheels and tabs. This mechanical substitution achieves reliable plug-in event tracking and threshold enforcement without the complexity of electronics, sensors, or power requirements, balancing reliability improvement with structural simplicity.
4Productivity
If the connector allows usage until failure point, then productivity is maximized, but loss of time increases due to unexpected failures and downtime
Solution Approach 1:
The connector disables itself preliminarily before actual failure occurs by tracking plug-in events and stopping operation at a predetermined threshold. This preliminary action prevents unexpected failures and the associated downtime for repair and replacement, ensuring continuous productivity by avoiding interruptive maintenance.
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
Effectively counts the number of plug-in events and prevents further usage once the threshold is reached, thereby extending the lifespan of the connector and reducing the risk of unexpected failures and downtime.
Implementation Method 1
An inner spring at the opposite end of the inner sleeve causes the inner sleeve to move through the gear wheel
Data Source
AI summary
A cable connector for counting a number of plug-in events and preventing further plug in attempts after a threshold number of plug-in events have occurred. An inner sleeve is located inside an outer sleeve, and is designed to move relative to the outer sleeve. The inner sleeve further includes a tab on an outer surface of the inner sleeve. A gear wheel is located inside the outer sleeve and perpendicular to the inner sleeve and has a number of gear teeth. A toggle plug counter rotates the gear wheel one tooth in response to a plug-in action of the cable counter. When the gear wheel rotates to a point where the tab aligns with a notch in the gear wheel an inner spring at the opposite end of the inner sleeve causes the inner sleeve to move through the gear wheel such that further plugging action becomes difficult.