Connector Interlocking Rotation Mechanism Reduces Fitting Force
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Solution Overview
Problem
Shutter-mechanism-equipped connectors in electric vehicles face challenges with increased fitting force due to rotation resistance and potential misalignment, leading to hindered assembly and larger connector sizes.
Innovation Solution
A connector design featuring a rotatable shutter and a rotation lever with an interlocking mechanism, where the mating connector's side surface presses the lever to rotate the shutter, reducing the fitting force and allowing smooth assembly without the need for increased connector size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tip end portion of the mating connector pushes the front surface portion of the shutter to rotate it outward, then the shutter opens to enable terminal coupling, but the fitting hood portion must be lengthened to accommodate the shutter opening trajectory, increasing connector size
Solution Approach 1:
The shutter rotation axis is changed from being parallel to the connector fitting direction to being perpendicular to it. This dimensional change allows the shutter to rotate in a different plane, eliminating the need for a long fitting hood portion while still achieving complete opening for terminal coupling.
Solution Approach 2:
Instead of pushing the front surface portion of the shutter to rotate it outward, the invention pushes the rear surface portion of the shutter. This inverted approach causes the shutter to rotate inward toward the housing, achieving the same opening function with a compact structure.
2Reliability
If the shutter is rotated and opened by a pressing force in the connector fitting direction, then terminal coupling is enabled, but rotation resistance against shutter rotation is added to insertion resistance, increasing fitting force
Solution Approach 1:
The shutter rotation is changed from occurring in the connector fitting direction to occurring perpendicular to it. This allows the pressing force to be applied in the fitting direction while the shutter rotates in a different plane, separating the fitting force from the rotation resistance and reducing the total force required.
Solution Approach 2:
The pressing force is applied to the rear surface portion of the shutter instead of the front surface portion. This inversion changes the rotation direction and allows the shutter to rotate inward, reducing the resistance moment and thereby reducing the fitting force required.
3Reliability
If the front surface portion of the shutter is pressed by the tip end portion of the mating connector, then the shutter opens for coupling, but the connector can be fitted from all angles including incorrect angles, hindering smooth assembly
Solution Approach 1:
The shutter and rotation lever are positioned asymmetrically within the housing rather than at the center. This asymmetric configuration creates a specific engagement geometry that guides the mating connector to the correct fitting position, preventing misalignment and ensuring smooth assembly.
4Force
If a rotation lever with interlocking mechanism is introduced to rotate the shutter, then fitting force is reduced and assembly is smoothed, but device complexity increases
Solution Approach 1:
The rotation lever is integrated with the shutter mechanism through an interlocking connection, merging the rotation function and shutter operation into a single coordinated mechanism. This reduces the number of separate components and simplifies the overall structure while achieving reduced fitting force.
Solution Approach 2:
The rotation lever acts as an intermediary element that translates the pressing force from the mating connector into shutter rotation. This mediator mechanism efficiently transmits force while controlling the rotation motion, reducing fitting force without requiring complex separate systems.
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 design reduces the fitting force and ensures smooth connector assembly by minimizing rotation resistance and eliminating the need for longer connector lengths, enabling efficient and correct fitting even when aligned incorrectly.
Implementation Method 1
a rotation lever that is disposed on one side portion side of the front opening and is rotatably supported to the housing about a rotation axis intersecting a connector fitting direction of the mating connector
Implementation Method 2
an interlocking rotation mechanism provided between the rotation lever and the shutter and configured to rotate the shutter in accordance with rotation of the rotation lever
Data Source
AI summary
A connector includes a housing configured to accommodate a connection terminal, a shutter that is rotatably provided in the housing and is configured to open and close a front opening of the housing, a rotation lever that is rotatably supported to the housing about a rotation axis, and an interlocking rotation mechanism provided between the rotation lever and the shutter and configured to rotate the shutter in accordance with rotation of the rotation lever. A pressing force of the mating connector, whose fitting tip end portion is moved to a position facing the front opening, acts on a lever front end portion of the rotation lever so as to rotate the rotation lever, and thus the shutter is rotated by the interlocking rotation mechanism so as to open the front opening.