Motor Test Bench Connector with Ball Joint Alignment
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Solution Overview
Problem
Existing connectors for motor test benches face challenges in maintaining reliable electrical contact due to production tolerances in electric motor supply plugs, leading to incomplete contact or mechanical damage, especially with varying plug positions and tilts.
Innovation Solution
A connector design featuring a movable connector head with a ball joint and an alignment unit comprising mechanical spring elements and controllable clamping jaws, allowing for precise adjustment and secure positioning to ensure reliable contact without mechanical stress on the supply plugs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the connector uses a fixed rigid structure, then the manufacturing precision is improved, but the reliability of electrical contact deteriorates due to production tolerances in motor supply plugs
Solution Approach 1:
The connector head is made movable relative to the connector frame through a ball joint, allowing dynamic adjustment to compensate for position and tilt variations in motor supply plugs. This dynamic structure enables the contact pins to automatically align with the plugs despite manufacturing tolerances, resolving the contradiction between fixed manufacturing precision and variable contact reliability.
Solution Approach 2:
The ball joint mechanism changes the positional parameters of the connector head, allowing it to adjust its position and orientation in space. This parameter adjustment enables the connector to adapt to the actual position and tilt of the motor supply plugs, ensuring reliable electrical contact despite variations in plug positioning.
2Reliability
If the connector head is made movable to compensate for tolerances, then the reliability of electrical contact is improved, but the device complexity increases
Solution Approach 1:
A ball joint is used to provide the necessary mobility of the connector head with minimal structural complexity. The ball joint is a well-established mechanical component that achieves complex spatial adjustment through a simple spherical connection, allowing the connector head to adapt to position and tilt variations without requiring multiple actuators or complex control systems.
Solution Approach 2:
The ball joint enables the connector head to automatically adjust its position and orientation through self-alignment mechanisms, eliminating the need for external actuators or complex control systems. The mechanical design allows the connector to self-correct for tolerance variations, reducing device complexity while maintaining reliability.
3Reliability
If the contact pins are pressed firmly to ensure complete contact, then the electrical contact reliability is improved, but the mechanical stress on supply plugs increases causing damage
Solution Approach 1:
The movable connector head with ball joint allows the contact pins to dynamically adapt to the actual position of supply plugs, achieving complete electrical contact through precise alignment rather than excessive force. This reduces mechanical stress on the plugs while ensuring reliable contact, as the pins make full contact through proper positioning rather than brute force.
Solution Approach 2:
The ball joint mechanism provides beforehand cushioning by absorbing position and tilt variations before they translate into mechanical stress on the supply plugs. The movable connector head compensates for tolerance variations in advance, allowing gentle contact that still achieves complete electrical connection without damaging the plugs.
4Ease of operation
If the connector head is fixed in position, then the ease of operation is improved, but the adaptability to production tolerances deteriorates
Solution Approach 1:
The ball joint provides automatic adaptation to position and tilt variations without requiring manual adjustment or complex control operations. The connector head moves passively to align with the supply plugs, maintaining ease of operation while achieving high adaptability to production tolerances.
Solution Approach 2:
The connector head performs self-alignment through the ball joint mechanism, automatically adapting to variations in plug position and tilt without external intervention. This self-service capability maintains operational simplicity while providing high adaptability to manufacturing tolerances.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures reliable and complete electrical contact between the connector's contact pins and the motor's supply plugs, preventing mechanical loads and damage, even with production tolerances, by allowing for precise alignment and secure fixation during both contact and disconnection.
Implementation Method 1
the connector head is fixed in position relative to the connector frame in the contact direction via a ball joint and is movably mounted in a plane perpendicular to the contact direction relative to the connector frame
Implementation Method 2
an alignment unit is provided for adjusting the connector head into a predetermined position relative to the connector frame, which is formed from a plurality of mechanical spring elements arranged between the connector head and the connector frame, the common equilibrium position of which defines a predetermined position of the connector head
Implementation Method 3
clamping jaws which are movable by means of controllable actuating cylinders between a releasing position, in which the connector head is movable in a plane perpendicular to the contact direction, and a clamping position, in which the connector head is fixed in a predetermined position by means of the clamping jaws
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A connector for a test unit (16) of a motor test bench, wherein electrically connected contact pins (1) of the connector, connected by electrical supply cables (5), are movable in a contact direction (R) for establishing and breaking an electrical contact with supply plugs (6) of an electric motor under test. It is proposed that the connector comprises a connector head (2) and a connector frame (4) movable in the contact direction (R), wherein the contact pins (1) are arranged on the connector head (2) and the connector head (2) is fixed in position relative to the connector frame (4) in the contact direction (R) via a ball joint (11) and is movably mounted in a plane perpendicular to the contact direction (R) relative to the connector frame (4), and an alignment unit is provided for adjusting the connector head (2) to a predetermined position relative to the connector frame (4).In this way, even if production tolerances occur on the part of the electric motor, a reliable and complete electrical contact can be established, thereby avoiding mechanical stresses and thus damage to the supply plugs (6).