Complex Connector Lock Assistant Mechanism
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Solution Overview
Problem
Conventional complex connectors face issues with time lag in disconnecting main and interlock circuits, leading to potential electric shocks and increased costs due to the use of springs, which also pose durability concerns.
Innovation Solution
The design integrates a lock assistant mechanism with cantilever members and projections to ensure a time difference in the disengagement of connectors, eliminating the need for springs and preventing erroneous fitting or disengagement orders, thereby ensuring safe and cost-effective operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If springs are used to connect the second contact elements to the second corresponding contact elements, then the connection is achieved, but the cost increases and durability deteriorates due to rust and aged deterioration
Solution Approach 1:
The patent removes the spring component entirely from the connector design. Instead of using springs to maintain contact pressure between the second contact elements and second corresponding contact elements, the invention employs a direct mechanical engagement structure where the male and female connector bodies themselves provide the necessary contact force through their geometric shapes and locking mechanisms.
Solution Approach 2:
The patent replaces expensive and durable spring components with simpler, cheaper plastic or metal connector bodies that achieve the same function through structural design rather than elastic deformation. This substitution reduces manufacturing cost while maintaining adequate service life for the application.
2Productivity
If the first contact elements and first corresponding contact elements are connected simultaneously with the second contact elements and second corresponding contact elements, then the connection is complete, but the risk of electric shock increases due to simultaneous power and signal connection
Solution Approach 1:
The patent divides the connector into two distinct functional segments: a main connector body for power transmission (first contact elements) and a separate interlock connector for signal transmission (second contact elements). This segmentation allows independent engagement and disengagement sequences, enabling the signal connection to be established after the mechanical connection is secure, thereby eliminating the electric shock hazard.
Solution Approach 2:
The patent implements a preliminary mechanical engagement phase where the main connector bodies connect first, establishing the structural bond before the interlock connectors engage to establish electrical signal connections. This preliminary action ensures that the mechanical support is in place before any electrical signals are transmitted, preventing electric shock risks.
3Productivity
If the second connector is connected before the first connector is completely connected, then the fitting process is faster, but the fitting order control is lost leading to potential safety issues
Solution Approach 1:
The patent employs a nested structure where the interlock connector (second connector) is positioned within or alongside the main connector body (first connector). The interlock connector is designed to engage only after the main connector bodies are properly aligned and connected, creating a natural sequential engagement process that maintains fitting order control while enabling rapid connection.
Solution Approach 2:
The patent uses dimensional differentiation in the connector design, where the main connector engagement occurs in one dimensional plane while the interlock connector engagement occurs in a different plane or at a different depth. This dimensional separation allows the operations to be visually and physically distinct, ensuring proper sequencing without compromising overall fitting speed.
Data Source
AI summary
A complex connector, comprises a male connector composed of a first male connector and the second male connector formed integrally with each other; a first female connector to which a second female connector and a lock assistant are attached in a movable manner, wherein the lock assistant includes an elongated cantilever member extending toward the first male connector, and a projection retaining engagement with the engagement portion of the first female connector is formed at a distal end of the elongated cantilever member, and in a condition in which the first male connector and the first female connector are disengaged from each other, the projection is retainingly engaged with the engagement portion, and in a condition in which the projection is retainingly engaged with the engagement portion, the projecting portion of the second female connector abuts against the abutment portion of the lock assistant.