High-Amperage Connector Visual Alignment Features
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Solution Overview
Problem
Connecting high-amperage multi-pin plugs and receptacles in industrial and commercial environments is challenging due to their size and multiple keys/keyways, often requiring a push-and-twist method that can cause damage when misaligned.
Innovation Solution
Incorporating visual alignment features such as grooves, notches, or keyway alignment features on the outer surfaces of connectors to facilitate easy alignment without damaging the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual alignment features are added to connectors, then alignment accuracy and connection safety improve, but device complexity increases
Solution Approach 1:
The patent creates a visual copy or representation of the keyway alignment requirements through alignment features (such as colored bands, markings, or geometric patterns) on the connector exterior. These features replicate the internal keyway orientation information in a visible form, allowing users to align connectors by matching external features rather than relying on trial-and-error insertion. This copying approach improves alignment accuracy without fundamentally changing the connector's core structure.
2Productivity
If the push-and-twist method is used to connect connectors, then connection speed improves, but the risk of component damage increases due to misalignment
Solution Approach 1:
The patent implements alignment features that enable users to perform preliminary alignment of the connectors before the actual connection action. By providing visible indicators (such as aligned markings, colored zones, or geometric alignment features) that show the correct relative position of male and female connectors, the system allows users to quickly establish proper orientation before pushing the connectors together. This preliminary visual alignment eliminates the need for corrective twisting and prevents damage from misaligned connections, while maintaining fast connection speed.
Data Source
AI summary
A high-amperage connector with visual alignment features is described. The connector can comprise a male connector with a male skirt where the male skirt has two keys on an outer surface. At least one of the keys on the outer surface of the male skirt can have an alignment feature. The connector also comprises a female connector with a female skin where the female skirt has two keyways on an inner surface of the female skirt. At least one of the keyways can have a corresponding alignment feature located on the outer surface of the female skirt. The alignment features on the male skirt and the female skirt allow a user to easily align the two connectors before connecting them.