Circular Modular Connector Angular Alignment
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Solution Overview
Problem
Existing high-density circular push-pull modular pluggable electrical connectors face challenges with accurate terminal engagement due to manufacturing tolerances, leading to high plugging forces and potential contact damage. Additionally, conventional cable clamps allow for slight cable movement, compromising the reliability of weld or solder connections.
Innovation Solution
The connector system incorporates angular alignment members and a slight angular play between the terminal unit and the casing, allowing for precise alignment during plugging. This system also features a robust cable anchoring mechanism with a cable grip sleeve and tightening nut, ensuring secure cable positioning and reducing movement during connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cable clamps are used to clamp the cable within the casing, then the cable can be secured to the connector, but slight movement of the cable occurs which compromises the reliability of weld or solder connections between the leads and contact pads
Solution Approach 1:
The cable grip mechanism transforms the cable securing approach by using a threaded engagement system that converts rotational motion into axial clamping force. The cable grip sleeve engages with the cable outer sheath through friction and mechanical interlocking, creating a stable anchor point that eliminates cable movement during connection and disconnection operations.
2Quantity of substance
If high density contact arrangement is implemented in circular push-pull modular pluggable connectors, then connection density is increased, but manufacturing tolerances cause angular position variations that lead to high plugging forces and potential contact damage
Solution Approach 1:
The connector design incorporates preliminary alignment features including angular alignment members on the casings and angular positioning members on the terminal units. These features pre-align the terminal units at defined angular positions before the actual contact engagement occurs, ensuring that high-density contacts engage accurately without requiring excessive plugging force to compensate for angular misalignment.
Solution Approach 2:
The terminal unit acts as an intermediary component between the casing and the contacts. It provides a stable mounting platform with precisely positioned angular alignment members that mediate the connection between the two casings, ensuring accurate angular positioning of high-density contacts while distributing mechanical stresses away from the fragile contact elements.
Data Source
Figure 1a~1c
Figure 1d
Figure 2a~2c
AI summary
Connector system comprising a first pluggable electrical connector (2) comprising a substantially circular casing (4) and a terminal unit (6) mounted within the casing, the terminal unit comprising a housing (8) with a module receiving cavity (37) formed within the housing, and a plurality of terminal modules (10) insertably received in the module receiving cavity (37) in a stacked arrangement, each terminal module comprising a plurality of contacts (18), and a mating second connector (2') pluggably connectable and disconnectable to the first connector, the mating second connector comprising a substantially circular casing (4') and a terminal unit (6') mounted within the casing, the terminal unit (6') comprising a housing (8') and a plurality of terminal modules (10') mounted in a stacked arrangement in said housing (8'), each terminal module comprising a plurality of contacts for pluggable connection to a corresponding said plurality of contacts (18) of said first connector. The terminal unit housing (8) of the first connector comprises angular positioning members (5) mating with complementary angular positioning members (5') on the terminal unit housing (8') of the second connector, the angular positioning members (5') and mating angular positioning members (5) configured to allow sliding insertion during plugging connection and to align the terminal units (6, 6') of the mating first and second connectors as they are plugged together.