Coded Plug-In Connector Modules for Error-Proof Assembly
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Solution Overview
Problem
Existing plug-in connector modules for modular connectors face challenges in flexible and variable combinability of contact inserts, leading to potential errors during assembly and the need for additional fixing elements.
Innovation Solution
A plug-in connector module design that includes module elements with specific codings and retaining contours, allowing for orientation-faithful arrangement and assembly, thereby preventing incorrect combinations and eliminating the need for additional fixing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If module elements are designed with coding for orientation-faithful arrangement, then assembly errors are reduced, but device complexity increases due to additional coding features
Solution Approach 1:
The coding features are integrated directly into the retaining contours of the module elements. The first and second codings are formed as part of the retaining contour structure, combining the retention function with the coding function in a single integrated feature, thereby reducing overall device complexity while maintaining assembly accuracy.
Solution Approach 2:
The retaining contours serve multiple functions: they provide mechanical retention for assembling module elements, establish orientation-faithful arrangement through coding, and enable error prevention through form-fitting interactions. This multi-functionality reduces the need for separate coding components.
2Adaptability or versatility
If retaining contours are designed for flexible combinability of contact inserts, then adaptability increases, but manufacturing precision requirements worsen due to tighter tolerances
Solution Approach 1:
The retaining contours are segmented into distinct coding features (first coding, second coding) that can be independently designed and manufactured. This segmentation allows for modular production where each coding feature can be optimized separately, reducing overall manufacturing precision requirements while maintaining flexible combinability.
3Device complexity
If additional fixing elements are eliminated through integrated retaining contours, then device complexity reduces, but strength of assembly worsens due to reduced fixing points
Solution Approach 1:
The retention and fixing functions are merged into the retaining contour structure. The form-fitting interaction between complementary retaining contours provides both retention and fixing in a single integrated feature, eliminating the need for separate fixing elements while maintaining assembly strength through the interlocking geometry.
Data Source
AI summary
A modular element for assembly with a further modular element to form a plug-in connector module is suitable for arrangement in an accurately oriented manner at a plug-in location of the plug-in connector module. The plug-in location has a coding of the arrangement of the plug-in connector module in a first direction and a plug-in direction of the modular element; and the modular element has a coding which corresponds to the coding of the plug-in location. The modular element has a further coding which corresponds to the coding of the modular element in such a way that it is ensured that an assembled plug-in connector module, which is unsuitable for the plug-in location, without the coding and a correspondingly faulty attempt when assembling two modular elements are precluded.