Rotating Connector Coupling Mechanism for Blind Mating
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Solution Overview
Problem
In high-reliability applications like military and aerospace, connectors face challenges in harsh environments due to vibration, temperature swings, moisture, and chemical contaminants, and often lack reliable feedback mechanisms for proper mating, especially in blind mating scenarios where visual indicators are obscured, leading to potential damage and false mating indications.
Innovation Solution
A connector design featuring a rotatable coupling mechanism with an inner and outer coupling nut, providing tactile and audible feedback through a detent system that engages ramped steps for verified engagement and preventing overtightening, along with a clutch mechanism to handle foreign objects and misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If visual indicators are used to indicate proper mating, then the installer can verify connector engagement, but in densely populated areas or blind mating scenarios, the indicators become obscured and unusable
Solution Approach 1:
The patent replaces visual indicators with a tactile feedback mechanism. A cam mechanism converts the rotational motion of the coupling nut into linear motion of a plunger that pushes against a tactile indicator on the connector housing. This mechanical substitution allows the installer to verify mating status through touch rather than sight, resolving the contradiction between providing mating information and maintaining visibility in obscured environments.
2Ease of operation
If the connector allows continuous rotation for mating, then the coupling mechanism is simple to operate, but the installer cannot detect when proper mating has been achieved and may overtighten
Solution Approach 1:
The patent implements a feedback mechanism where a cam profile, as it rotates with the coupling nut, progressively pushes a plunger outward against a spring. When the cam completes its rotation and returns to its starting position, the plunger is pushed to its maximum outward position, providing tactile feedback that mating is complete. This feedback loop allows continuous rotation for ease of operation while reliably indicating when proper mating has been achieved.
Solution Approach 2:
The cam mechanism creates a periodic tactile feedback pattern during rotation. The plunger engages and disengages from the cam profile in a repeating cycle, with each cycle providing a distinct tactile sensation. This periodic action gives the installer rhythmic feedback during the mating process, making it easy to detect when the full rotation is complete and proper mating has been achieved.
3Device complexity
If a single coupling nut is used, then the device complexity is reduced, but the mechanism cannot provide both tightening control and mating verification feedback
Solution Approach 1:
The patent merges two functions into a single integrated coupling nut: the tightening function (threaded engagement with the mating connector) and the verification function (cam-driven tactile feedback). The coupling nut simultaneously performs both operations, eliminating the need for separate components while providing reliable mating verification. This merging resolves the contradiction by achieving both simplicity and reliability through functional integration.
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 secure connector engagement with verified mating feedback, preventing damage from overtightening and foreign objects, and allowing for blind mating in dense environments while maintaining high-quality electrical and optical characteristics.
Implementation Method 1
The detent is positioned rearward of the rear of the inner coupling nut and successively engaging the ramped steps as the outer coupling nut is rotated in a tightening direction
Data Source
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AI summary
A connector (502) includes a shell (506) and a coupling mechanism (504) rotatably coupled thereto. The coupling mechanism includes an inner coupling nut (520) and an outer coupling nut separate (522) from the inner coupling nut. The inner coupling nut has internal threads (505) configured to be threadably coupled to a mating connector. The inner coupling nut has a plurality of ramped steps (534) disposed at different circumferential positions along the rear (532). The outer coupling nut has a detent (560) successively engaging the ramped steps as the outer coupling nut is rotated in a tightening direction. The detent is released from the corresponding ramped step when the connector is fully mated to the mating connector. The detent engages a corresponding ramped step as the outer coupling nut is rotated in an untightening direction causing the inner coupling nut to rotate in the untightening direction.