Electrical Connector Handles With Coupling Features
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Solution Overview
Problem
Larger electrical connectors are difficult to lift and manage due to their weight, and existing handles can cause mechanical strain and dislodgment of connector ends, leading to potential damage and disruption of electrical continuity.
Innovation Solution
The design includes handles with coupling features that align and couple with complementary features on the connector ends, allowing for secure handling and reduced risk of mechanical damage, while providing visual indication of proper coupling and facilitating safe manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If handles are affixed to connector ends to help lifting and manipulation, then ease of operation is improved, but mechanical strain and dislodgment of connector ends can occur leading to potential damage
Solution Approach 1:
A coupling feature is introduced as an intermediary element between the handle and connector body. This coupling feature distributes mechanical loads and provides a secure mechanical interface that prevents direct strain transmission to the connector end, thereby maintaining both ease of handling and mechanical integrity
Solution Approach 2:
The handle assembly is segmented into distinct components: the handle itself, the coupling feature, and the connector body interface. This segmentation allows each component to be optimized independently - the coupling feature can be designed specifically to distribute loads and prevent dislodgment while the handle provides lifting capability
2Adaptability or versatility
If larger sized electrical connectors are used to terminate large cables and conductors, then functionality is improved, but weight increases making them difficult to lift and manage
Solution Approach 1:
The connector system is segmented into two main parts: the heavy connector bodies that provide the necessary functionality for large cables, and the separate handles that provide lifting capability. This allows the connector bodies to be optimized for their electrical function without compromising on portability, as the handles can be attached only when needed for installation or repositioning
Solution Approach 2:
The handle acts as a counterbalancing element that provides mechanical advantage for lifting the heavy connector bodies. By providing a lever arm and secure coupling point, the handle effectively counteracts the weight of the large connector, making it manageable despite its substantial mass
3Ease of operation
If handles are added to connector ends, then ease of manipulation is improved, but alignment precision may be compromised
Solution Approach 1:
The coupling feature serves as a precision intermediary that ensures accurate alignment between the handle and connector body. It provides defined mechanical interfaces with tight tolerances that maintain alignment precision while still allowing for the addition of the handle for improved manipulation
Solution Approach 2:
The coupling feature is designed to self-align during the attachment process, using geometric constraints and tolerance stacking to automatically ensure proper alignment between the handle and connector body without requiring additional alignment procedures or compromising manufacturing precision
Data Source
AI summary
An electrical connector is described herein and can include a first connector end and a second connector end removably coupled to the first connector end. The first connector end can include a first collar forming a first cavity, where the first collar comprises a connector coupling feature. The first connector end can also include a first handle disposed on a first outer surface of the first collar, wherein the first handle comprises a handle coupling feature. The second connector end can include a second collar forming a second cavity, where the second collar includes a complementary connector coupling feature, where the connector coupling feature of the first connector end couples with the complementary connector coupling feature of the second connector end. The second connector end can also include a second handle disposed on a second outer surface of the second collar that includes a complementary handle coupling feature.