Connector Assembly Adjustable Contact Pressure
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Solution Overview
Problem
Existing connector assemblies for high current and medium voltage electric circuits are expensive to produce and require reliable connections over a long lifetime, with existing solutions not adequately addressing the need for adjustable contact pressure and manufacturing tolerance issues.
Innovation Solution
A connector assembly featuring a cable terminal with a contact ring and an inner plug, where the outer plug is movable and includes a thrust face that clamps the contact section between the outer plug and the contact ring, allowing for adjustable contact pressure and improved reliability through screw threads and optional features like embossments and inclined surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring contacts are used to provide separable electric connections, then reliable electrical connections over long lifetime and high switch cycles are achieved, but production cost increases due to expensive surface platings such as silver platings
Solution Approach 1:
The patent replaces expensive spring contacts with a clampable contact system using standard metal parts that can be repeatedly clamped and disconnected without degradation. The contact section is clamped between the outer plug and contact ring using screw threads, eliminating the need for expensive silver platings while maintaining reliable electrical connections over long lifetimes.
2Manufacturing precision
If the contact section is clamped between the outer plug and contact ring with screw threads, then adjustable and defined contact pressure is achieved, but device complexity increases due to additional screw thread components
Solution Approach 1:
The screw threads serve multiple functions: they provide the clamping mechanism to hold the contact section, they enable adjustment of contact pressure, and they facilitate assembly and disassembly. The outer plug's second screw thread mates with the contact ring's first screw thread, creating a universal fastening system that achieves defined contact pressure without requiring separate adjustment mechanisms.
Data Source
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AI summary
A connector assembly (10) comprises a cable terminal (200) having a contact ring (210), an inner plug (400) having a contact section (440) and an outer plug (500) being movable in a longitudinal direction (11). The contact section (440) can be clamped between the outer plug (500) and the contact ring (210).