Connector Fitting Prevention with Slanted Beak Geometry
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Solution Overview
Problem
Connectors with a connector position assurance lock (CPA) and packing experience increased insertion force when a short spring is included, and this issue is exacerbated when multiple terminals are present, leading to inefficient fitting operations.
Innovation Solution
Incorporating a draw-in slanted surface on the male beak and a leading-end slanted surface on the female lock, which utilize restoring forces to reduce insertion force and ensure one-action property, even with a short spring and multiple terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a short spring is added to the connector to improve contact reliability, then the connector position assurance is enhanced, but the insertion force increases significantly
Solution Approach 1:
The draw-in slanted surface performs preliminary action by converting the insertion motion into a restoring force that activates before the short spring is fully compressed. This preliminary action reduces the peak insertion force by utilizing the slanted surface geometry to gradually engage the short spring, rather than allowing abrupt compression that would create force spikes.
Solution Approach 2:
The slanted surface introduces a curved geometric element that transforms the linear insertion force into a distributed force profile. The angular geometry of the slanted surface creates a mechanical advantage by redirecting the insertion force through a controlled path, reducing the peak force required to compress the short spring while maintaining reliable contact.
2Adaptability or versatility
If multiple terminals are included in the connector to increase functionality, then the connector versatility is improved, but the total insertion force increases
Solution Approach 1:
The draw-in slanted surface performs preliminary action by converting the insertion motion into a restoring force that activates before the short spring is fully compressed. This preliminary action reduces the peak insertion force by utilizing the slanted surface geometry to gradually engage the short spring, rather than allowing abrupt compression that would create force spikes.
Solution Approach 2:
The slanted surface introduces a curved geometric element that transforms the linear insertion force into a distributed force profile. The angular geometry of the slanted surface creates a mechanical advantage by redirecting the insertion force through a controlled path, reducing the peak force required to compress the short spring while maintaining reliable contact.
3Manufacturing precision
If a CPA lock mechanism is added to prevent incomplete fitting, then the fitting accuracy is improved, but the device complexity increases
Solution Approach 1:
The CPA lock mechanism merges the locking function with the existing connector housing structure. The lock arm is integrated into the housing rather than being a separate component, and the locking action is combined with the natural insertion motion, eliminating the need for separate locking mechanisms while maintaining fitting accuracy.
Solution Approach 2:
The CPA lock mechanism operates automatically through the insertion motion itself. The lock arm engages with the connector body during the natural insertion process without requiring additional manual operations or complex control systems, allowing the connector to self-lock upon proper insertion.
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 solution effectively minimizes insertion force and maintains incomplete fitting prevention functionality, ensuring smooth and efficient connector fitting without excessive force, even with additional components like short springs and multiple terminals.
Implementation Method 1
a restoring force for returning the female lock to its original position serves as a driving force for fitting the connector when the female lock reaches the draw-in slanted surface
Implementation Method 2
one-action property is secured by using a restoring force for returning the CPA lock to its original position as the driving force when the CPA lock reaches the leading-end slanted surface
Data Source
AI summary
An incomplete fitting prevention connector includes a first connector, a second connector that is fitted to the first connector, and a connector position assurance lock that is slidably mounted to an outer side of the second connector. The first connector includes a male beak, a short spring and a terminal. The second connector includes a female lock passing over the male beak and a short-circuit removal plate part inserted between the short spring and the terminal. A draw-in slanted surface is formed at a leading end of the male beak, a restoring force for returning the female lock to its original position serves as a driving force for fitting the connector when the female lock reaches the draw-in slanted surface, and the insertion force of the short-circuit removal plate part applied between the short spring and the terminal is reduced.