Coding Clip for Connector Foolproofing and Assembly
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Solution Overview
Problem
Conventional connector systems require excessive time and cost for assembly and disassembly, especially in industrial applications, due to complex mating mechanisms and foolproofing mechanisms that increase production and logistical costs.
Innovation Solution
A coding clip system that allows for quick and secure mating of connectors without additional locking means, featuring a form-fitting design with a detachable coding shape that can be easily exchanged, reducing production costs and simplifying the assembly process by externalizing foolproofing functions from the plug to a separate clip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coupling screw solutions or lever mechanisms are used to ensure robust mating of connectors, then the reliability of the electrical connection is improved, but the assembly time and operational complexity increase significantly
Solution Approach 1:
The connector assembly is divided into separate functional components: a plug, a connector body, and a distinct locking element that can be independently manipulated. This segmentation allows the locking mechanism to be activated separately from the insertion process, enabling rapid assembly while maintaining secure connection.
Solution Approach 2:
The locking function is extracted as a separate element from the plug and connector body. The locking element can be independently engaged or disengaged, allowing the plug to be quickly inserted and removed while the locking mechanism provides secure attachment when needed. This separation eliminates the need for complex multi-step locking procedures.
2Reliability
If fool proofing mechanisms with molded coding shapes are integrated into connectors, then the risk of unintended mating is reduced, but the production and logistical costs increase
Solution Approach 1:
The coding shape is extracted from the plug and integrated into the locking element instead. This allows the coding feature to be added to a smaller, simpler component that can be manufactured more cost-effectively. The locking element with integrated coding shape can be produced using simpler molding processes compared to molding coding features directly into the entire plug assembly.
Solution Approach 2:
The coding shape is replicated on the locking element to provide the same fool-proofing function as would be present on the plug itself. This copying approach allows the coding feature to be implemented on a smaller component, reducing manufacturing complexity and cost while maintaining the same level of assembly verification.
3Reliability
If coding shapes are molded directly onto plugs, then fool proofing is integrated, but the production costs and logistical complexity of managing multiple coded plug variants increase
Solution Approach 1:
The connector system is segmented into standardized plugs and customized locking elements. The coding variability is confined to the locking element rather than the plug itself. This allows a single standardized plug design to work with multiple coded locking elements, significantly reducing the number of plug variants that need to be manufactured and managed.
Solution Approach 2:
The coding feature is extracted from the plug and placed on the locking element. This extraction allows the plug to remain a simple, standardized component while the coding complexity is isolated to the locking element. Consequently, manufacturers only need to produce different coded versions of the locking element, not different coded plugs, reducing inventory complexity.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The invention relates to a coding clip for a fool proofing of the mating of a first connector with a second connector along a mating direction. The coding clip is configured to be slipped over and form-fitted on, in particular clipped on, a plug extending in the mating direction. The coding clip comprises a proximal portion with respect mating direction that is configured to lock the plug with the first connector, and a distal portion with respect mating direction that comprises a coding shape configured to be matched to a matching coding shape of the mating second connector.