Electrical Connector Core Rotation for Stiff Cable Routing
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Solution Overview
Problem
High forces during handling and routing of thick, stiff electrical cables in high-voltage and high-current applications can damage electrical connectors and cables, complicating the connection process.
Innovation Solution
An electrical connector design featuring a rotatable core assembly within a housing assembly, including a contact assembly, finger protection, and cable retention, which minimizes torsional load transfer and facilitates easier handling by allowing 360-degree rotation, reducing the effort and risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If thick and stiff electrical cables are used for high-voltage and high-current applications, then power transmission capability is improved, but handling difficulty and risk of damage increase
Solution Approach 1:
The core assembly is designed to rotate freely within the housing assembly, allowing dynamic adjustment during handling and routing operations. This rotational freedom enables the connector to adapt to different cable routing paths without requiring manual manipulation of the stiff cable, thereby improving ease of operation while maintaining high power transmission capability
Solution Approach 2:
The connector is divided into separable components: a housing assembly and a rotatable core assembly. This segmentation allows the core assembly to be independently rotated to facilitate cable routing, while the housing remains stationary, resolving the contradiction between cable stiffness and handling ease
2Ease of operation
If manual handling is used for electrical connectors, then flexibility is improved, but risk of damage to connector and cable increases
Solution Approach 1:
The rotatable core assembly provides automatic adaptation to routing requirements, reducing the need for forceful manual manipulation. The rotational mechanism allows the connector to self-adjust during installation, maintaining handling flexibility while minimizing damage risk through controlled movement
Solution Approach 2:
The rotational mechanism acts as an intermediary between the handler and the cable, absorbing and redirecting forces that would otherwise be transmitted directly to the cable and connector components. This mediator function reduces peak forces and prevents damage while maintaining operational flexibility
3Ease of operation
If rotational freedom is provided for the core assembly, then ease of routing is improved, but structural complexity increases
Solution Approach 1:
The rotational mechanism is implemented through simple geometric features (rotational surfaces, clearance gaps) rather than complex mechanical joints. This allows 360-degree rotation and maintains routing ease while keeping the structural complexity low through elegant simplicity
Data Source
AI summary
An electrical connector configured to be mated to a mating connector includes a housing assembly and a core assembly held rotatably within the housing assembly. The core assembly includes a contact assembly having a contact configured to electrically contact a mating contact of the mating connector, a finger protection assembly configured to at least partially cover the contact assembly, and a cable retention assembly configured to be attached onto an electrical cable.