Clamped Plug-In Connector Assembly for Vibration-Resistant Contacts
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Solution Overview
Problem
Existing electrical plug connections in the automotive industry face challenges with vibration resistance, leading to increased transfer impedance and reduced service life due to mechanical stress, particularly in high-voltage applications where vibrations from uneven roads and engine synchronization cause abrasion between plug and mating contacts.
Innovation Solution
A clamping device is integrated into the electrical plug connection to directly clamp the plug connector and mating plug connector together, providing mechanical stabilization by distributing forces directly between them, thus preventing contact abrasion and enhancing vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a primary locking device is used to connect the plug connector and mating connector, then the connection is secured against accidental disconnection, but relative movement between the connectors under vibration loads cannot be completely suppressed, leading to contact abrasion
Solution Approach 1:
The connection system is divided into two independent functional components: a primary locking device for preventing disconnection and a clamping device for suppressing relative movement. This segmentation allows each component to optimize its specific function without compromising the other, resolving the contradiction between connection security and contact abrasion prevention.
Solution Approach 2:
The clamping device is integrated into the existing connector structure, with clamping elements that cooperate with the mating connector to provide additional mechanical stabilization. This merging of functions into a unified connector assembly enables simultaneous achievement of secure connection and vibration resistance without requiring separate external components.
2Reliability
If a second fixing means is used to secure the connector to the outer housing, then vibration resistance is improved by stabilizing the connector relative to the socket, but installation space requirements increase and the solution is not sufficiently effective in practice
Solution Approach 1:
The clamping device utilizes the existing mating connector structure as part of the stabilization system, eliminating the need for separate external fixing means. The clamping elements engage with features already present on the mating connector, thereby improving vibration resistance without increasing installation space requirements or overall system complexity.
Solution Approach 2:
The mating connector serves dual functions: electrical connection and mechanical stabilization. By designing the clamping elements to cooperate with existing features on the mating connector, the system achieves multi-functionality without requiring additional components, thus resolving the contradiction between vibration resistance and device complexity.
3Object-affected harmful factors
If the connector is clamped directly to the mating connector, then contact abrasion is prevented by stabilizing the connection, but the clamping force must be sufficiently high to suppress relative movement under critical vibrations
Solution Approach 1:
The clamping elements are positioned to engage with specific localized features on the mating connector, concentrating the clamping force at optimal points to maximize stabilization effectiveness. This localized engagement prevents relative movement at the contact interfaces without requiring uniformly high clamping force across the entire connector assembly.
Solution Approach 2:
The clamping elements are designed with curved or conformal contact surfaces that match the geometry of the mating connector features. This geometric compatibility distributes the clamping force more effectively across the contact interfaces, enhancing stabilization while reducing the peak forces required compared to flat or mismatched contact surfaces.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a clamping device (5) for an electrical plug-in connection (1), which has an electrical plug-in connector (2), an electrical mating plug-in connector (3) that can be electrically and mechanically connected to the plug-in connector (2), and a primary latching arrangement (4) for latching the connection between the plug-in connector (2) and the mating plug-in connector (3). Provision is made for the clamping device (5) to be designed to brace the plug-in connector (2) and the mating plug-in connector (3) relative to one another in their connected state in addition to the latching by way of the primary latching arrangement (4).