Circular Connector Locking Element Structure for Automated Contact Assembly
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Solution Overview
Problem
Existing circular connectors with cable managers are difficult to automatically equip with contact elements, as they require more effort and complexity in securing the contact elements within the insulating body.
Innovation Solution
The electrical circular connector features an insulating body with integrally bonded locking elements, including a living hinge design and web elements, which simplifies the positioning and securing of contact elements without significant protrusions, facilitating easier automated equipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a cable manager with longitudinal pin is used to organize electrical strands, then cable organization and cable length management are improved, but the difficulty of automatically equipping the connector increases
Solution Approach 1:
The connector is divided into functionally independent modules: cable manager for strand organization, contact carrier for contact element arrangement, and insulating body for structural support. This segmentation allows each module to be optimized independently, with the contact carrier designed specifically for automated contact element insertion while the cable manager handles strand organization separately.
Solution Approach 2:
The contact carrier acts as an intermediary component between the cable manager and the insulating body. It receives organized electrical strands from the cable manager, positions contact elements onto the strands, and transfers the assembled units to the insulating body. This intermediary structure enables automated equipping by decoupling the cable management function from the contact element insertion function.
2Reliability
If locking elements with significant protrusion are used to secure contact elements, then contact element fixation is improved, but the insertion into housing becomes more difficult
Solution Approach 1:
The locking elements are designed with movable characteristics, allowing them to flex or deform during the insertion process. This dynamic behavior enables the locking elements to temporarily reduce their protrusion size for easy insertion into the housing, then engage and lock contact elements securely once inside. The living hinge connection provides this dynamic capability, allowing the locking element to adapt its shape during different operational phases.
Solution Approach 2:
The locking elements are integrated within the insulating body structure, with the living hinge connection allowing them to nest within the insulating body when not in use. This nesting arrangement minimizes the overall protrusion during insertion while maintaining the ability to extend and engage contact elements securely after insertion.
3Manufacturing precision
If integrally bonded locking elements are used to secure contact elements, then contact element positioning is improved, but the complexity of the insulating body structure increases
Solution Approach 1:
The locking elements are integrally bonded to the insulating body, merging two previously separate components into one. This integration ensures precise relative positioning between the locking elements and the insulating body, eliminating positioning errors that would arise from separate assembly. The living hinge connection provides this integral bonding while maintaining the functional independence of the locking elements.
Solution Approach 2:
The insulating body is designed to perform multiple functions: providing structural support, guiding contact element insertion through through-openings, and integrating locking elements for secure fixation. By combining these functions into a single multi-functional component, the overall device complexity is reduced compared to using separate components for each function.
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 design allows for quick and simple equipping of contact elements within the insulating body, enhancing automation capabilities and reducing the effort required for assembly, while maintaining stability and secure engagement of the locking elements.
Implementation Method 1
The design described herein therefore has a thin connection between the insulating body and a locking element. This thin/thin-walled connection allows the locking element to pivot around/on the insulating body.
Data Source
AI summary
An electrical circular connector is provided including a housing for accommodating an insulating body that has a substantially cylindrical outer shape, wherein the body is designed to accommodate at least one contact element and can be brought into engagement with at least one locking element which secures the contact element, at least in the axial direction, in its position in the insulating body, and wherein the locking element is integrally joined to the insulating body and, in a locked position, substantially fits into the cylindrical outer shape of the insulating body.