Motion-Reversing Connector Coupling for Robust Push-In Mating
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Solution Overview
Problem
Industrial connectors, particularly in aeronautical and military applications, face issues with reliability due to vibrations and mechanical stress, leading to degraded electrical contacts and prolonged assembly/disassembly times, and conventional foolproofing mechanisms increase production and logistical costs.
Innovation Solution
A connector design featuring an inner and outer housing element with a motion-reversing mechanical system, including lever beams and a coupling element, allows for secure mating through a simplified three-step process, and a coding clip ensures foolproof connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional screw coupling solutions are used to ensure robust mating, then reliability is improved, but device complexity and ease of operation deteriorate
Solution Approach 1:
The invention extracts and eliminates the screw coupling mechanism from the connector assembly, replacing it with a direct push-in mating system where the coupling element integrates the plug reception and locking functions within the housing structure itself
Solution Approach 2:
The coupling element merges multiple functions into a single integrated component: it provides plug reception, mechanical coupling, and locking capabilities all in one element that moves axially within the housing, eliminating the need for separate screw mechanisms
2Ease of operation
If lever mechanisms with locking devices are used for screw-less mating, then ease of operation is improved, but assembly time and device complexity worsen
Solution Approach 1:
The invention removes the lever mechanism and separate locking device from the connector design, simplifying the mating operation to a single direct push-in motion that achieves both connection and locking simultaneously
Solution Approach 2:
Instead of using a lever that moves perpendicular to the mating axis to engage a locking mechanism, the invention inverts the approach by using direct axial movement of the coupling element that inherently provides both connection and locking in the same motion direction
3Reliability
If molded coding shapes are provided on connectors for foolproofing, then reliability is improved, but manufacturing cost and device complexity worsen
Solution Approach 1:
The coupling element serves multiple functions: it provides the mechanical coupling interface, enables the foolproofing coding system through its geometric shape, and integrates the locking mechanism, thereby reducing the need for separate dedicated components for each function
Solution Approach 2:
The invention uses geometric parameter variations of the coupling element (such as D-shaped, oval, or rectangular cross-sections) to encode different connector types and prevent incompatible matings, replacing complex molded coding shapes with simpler dimensional variations
Data Source
AI summary
A connector matable along a mating axis with a mating connector includes an inner housing element having a receptacle, an outer housing element movable along the mating axis to the inner housing element from an unmated position of the outer housing element to a mated position of the outer housing element, and a coupling element with a hollow receiving and coupling with a plug of the mating connector. The coupling element is arranged inside the receptacle of the inner housing element and is movable along the mating axis from an unmated position of the coupling element to a mated position of the coupling element. The coupling element is connected to the outer housing element by a motion-reversing mechanical system and movement of the outer housing element in one direction along the mating axis moves the coupling element in an opposite direction relative to the inner housing element.