Electrical Connector Cam Assist for Low-Force Axial Mating
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Solution Overview
Problem
Existing electrical connector systems require high mating forces, making them ergonomically challenging and prone to improper mating and damage, especially as vehicle electrical content increases, leading to the need for bolted connections or cumbersome lever systems.
Innovation Solution
A connector system featuring a cam member with an offset engaging lug and a user moveable member with a cam slot and strap, allowing for ergonomic force feedback and reduced forward slider travel, enabling easier assembly and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If higher I/O connections per system are implemented to reduce the number of connection systems, then the overall system integration is improved, but the mating forces become excessively high making hand-mating ergonomically unacceptable
Solution Approach 1:
A cam member is introduced as an intermediary mechanism between the connector housing and the mating process. The cam member converts axial insertion force into rotational motion, which then translates to controlled mating force through the cam slot and lever arm, enabling high I/O connections while maintaining ergonomic hand-mating capabilities
Solution Approach 2:
The mating system transitions from static direct connection to dynamic cam-based motion transformation. The cam member rotates during insertion, creating a dynamic force transformation mechanism that reduces peak mating forces while maintaining secure connection, making high-density connectors ergonomically mateable by hand
2Ease of operation
If lever mating systems are used to reduce mating forces to ergonomic levels, then ease of operation is improved, but the device complexity increases due to pre-positioning requirements and multi-step processes
Solution Approach 1:
The cam member integrates multiple functions into a single component: it provides the lever arm for force multiplication, defines the cam slot for motion control, and incorporates the engaging lug for secure attachment. This merging eliminates the need for separate pre-positioning mechanisms and multi-step processes required by traditional lever systems
Solution Approach 2:
The engaging lug with chamfered leading edge performs preliminary alignment and guide the cam member into the cam slot during insertion. This preliminary action eliminates the need for separate pre-positioning steps required by traditional lever mating systems, reducing process complexity while maintaining ergonomic force levels
3Ease of manufacture
If traditional connector designs are used, then manufacturing simplicity is maintained, but improper mating and mating damage occur due to high forces
Solution Approach 1:
The cam slot is designed with a curved profile that guides the cam member through a controlled rotational path during insertion. This curvature transforms the linear insertion motion into rotational motion, distributing mating forces over a longer duration and reducing peak forces that cause improper mating and damage, while maintaining manufacturing simplicity
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
The system reduces mating forces to ergonomically acceptable levels, enhances assembly efficiency, and allows for more compact designs, improving usability and space savings in automotive applications.
Implementation Method 1
the engaging lug having a chamfered leading edge configured to lift the strap as the engaging lug is inserted into the first cam slot, the user moveable member configured to rotate the cam member via movement of the engaging lug through the first cam slot
Data Source
AI summary
A connector system may include a connector having a connector housing. The connector system may include a cam member rotatably attached to the connector housing. The cam member may define an engaging lug offset from an axis of rotation of the cam member. A connector system may include user moveable member slidably attached to the connector housing. The user moveable member may define a first cam slot inboard having a strap across an entrance portion of the first cam slot in which the engaging lug is received. The engaging lug has a chamfered leading edge that is configured to lift the strap as the engaging lug is inserted into the first cam slot. The user moveable member is configured to rotate the cam member via movement of the engaging lug through the first cam slot. A method of assembling a connector system also presented.