Circular Modular Connector With Self-Alignment and Cable Grip
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Solution Overview
Problem
High-density pluggable electrical connectors face issues with inaccurate terminal engagement due to manufacturing tolerances, leading to high plugging forces and potential damage, and require secure cable anchoring to prevent movement and weld/solder connection failures.
Innovation Solution
The connector system features angular alignment members and a cable grip mechanism with elastic gripping arms to ensure precise angular alignment and secure cable anchoring, allowing for low-mating-force plugging and reliable electrical interconnection, with optional angular play in terminal units and modules for self-alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cable clamps are used to secure the cable, then the cable can be anchored to the casing, but the cable still experiences slight movements that can lead to weld or solder connection failures
Solution Approach 1:
The cable grip mechanism transforms the cable anchoring from a rigid fixed-position clamp to a flexible elastic grip system. The elastic gripping arms can deform to accommodate cable position variations while maintaining secure contact, changing the mechanical parameter from rigid constraint to elastic constraint that absorbs movement without failing the weld/solder connections.
Solution Approach 2:
The elastic gripping arms are designed to provide cushioning before cable movement can cause damage. The elasticity of the gripping arms absorbs the shock and movement stresses that would otherwise transmit to the weld or solder connections, preventing connection failures in advance.
2Quantity of substance
If high-density contact arrangements are implemented, then the connector achieves high connection density, but manufacturing tolerances cause angular misalignment leading to high plugging forces and potential contact damage
Solution Approach 1:
The terminal unit is designed with rotational freedom relative to the casing, transforming the alignment system from static (fixed angular position) to dynamic (adjustable angular position). This allows the terminal unit to self-align with the mating connector during plugging, accommodating manufacturing tolerances in the angular positions of both the terminal unit and terminal modules while maintaining high contact density.
Solution Approach 2:
The system enables self-alignment through the inherent angular play between components. During the plugging process, the terminal unit and terminal modules automatically adjust their angular positions to achieve proper alignment without requiring external adjustment mechanisms, reducing plugging forces and preventing contact damage.
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
The solution enables reliable, low-force plugging and unplugging with secure cable anchoring, reducing the risk of contact damage and ensuring high-density electrical connections, while allowing for versatile configurations and easy maintenance.
Implementation Method 1
a cable grip mechanism with elastic gripping arms to ensure precise angular alignment and secure cable anchoring
Data Source
AI summary
Connector system comprising a first pluggable electrical connector comprising a substantially circular casing and a terminal unit mounted within the casing, the terminal unit comprising a housing with a module receiving cavity formed within the housing, and a plurality of terminal modules insertably received in the module receiving cavity in a stacked arrangement, each terminal module comprising a plurality of contacts, and a mating second connector pluggably connectable and disconnectable to the first connector, the mating second connector comprising a substantially circular casing and a terminal unit mounted within the casing, the terminal unit comprising a housing and a plurality of terminal modules mounted in a stacked arrangement in said housing, each terminal module comprising a plurality of contacts for pluggable connection to a corresponding said plurality of contacts of said first connector.