Connector Lever and CPA Locking for Error-Proof Plug Assembly
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Solution Overview
Problem
Existing electrical connectors lack efficient and reliable mechanisms for ensuring uniform, secure, and quick assembly, particularly in safety-critical applications like the electromobility sector, with a need for improved assembly processes and reduced risk of errors.
Innovation Solution
An arrangement for electrical connectors featuring a lever and a connection position assurance (CPA) that moves through distinct positions to secure the lever in the final plugging disposition, allowing for intuitive operation and reliable assembly, with mechanisms to prevent accidental movements and ensure correct positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lever is used as a plugging aid to ensure uniform and secure connection, then the reliability of the plug connection is improved, but the device complexity increases due to the additional moving parts and positioning mechanisms required
Solution Approach 1:
The CPA is divided into distinct functional segments: a lever component for positioning, a locking component for securing, and a positioning element for alignment. These segments work together but can be analyzed and manufactured separately, reducing overall system complexity while maintaining reliability.
Solution Approach 2:
The CPA incorporates movable elements including a lever that can pivot between positions and a positioning element that moves along a defined path. This dynamic design allows the mechanism to transition through different states (unplugged, plugging, locked) reliably while using simple geometric constraints rather than complex control systems.
2Reliability
If a CPA is added to secure the lever in the final plugging disposition, then the reliability of the assembled state is improved, but the ease of operation deteriorates due to additional steps and positions to manage
Solution Approach 1:
The positioning element is pre-configured with a defined movement path and geometric features that automatically guide it into the correct position as the lever moves. This preliminary setup eliminates the need for manual alignment or complex control during operation, maintaining ease of use while ensuring reliable positioning.
Solution Approach 2:
The CPA design allows the lever itself to drive the positioning element along its path through the natural motion of plugging. The mechanism serves itself by using the plugging motion to automatically position and lock the CPA, reducing the operational steps required while maintaining security.
3Manufacturing precision
If the CPA is made movable through distinct positions (delivery, ready-to-lock, locking), then the reliability of positioning is improved, but the device complexity increases due to multiple positions and states to manage
Solution Approach 1:
The CPA features asymmetric geometric design where the positioning element has a specific shape that interacts with corresponding asymmetric features on the lever and housing. This asymmetry creates naturally defined positions through geometric constraints rather than requiring symmetric, equally complex positioning mechanisms for each state.
Solution Approach 2:
The positioning element moves along a defined path that incorporates motion in multiple dimensions (rotation and translation). By utilizing multidimensional motion space, the CPA achieves precise positioning through the combination of movement types rather than requiring complex mechanisms in a single dimension.
Data Source
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AI summary
The invention relates to an arrangement (1) for an electrical connector (23) that can be plugged together with a mating connector (9), with a housing (15), with a lever (3) that is attached to the housing (15) to be movable between a pre-plugging disposition (13) and a final plugging disposition (11), with a connector position assurance (CPA) (5) that is movably attached to the lever (3) and that can be moved from a delivery position (49) through a ready-to-lock position (55) to a locking position (65), wherein the CPA (5) secures the lever (3) in the final plugging disposition (11) to the housing (15) when in the locking position (65), wherein the lever (3) can be moved from the final plugging disposition (11) to the pre-plugging disposition (13) when the CPA (5) is in the delivery position (49), wherein the CPA (5) can be moved from the delivery position (49) to the ready-to-lock position (55) when the lever (3) is in the pre-plugging disposition (13) and the lever (3) can be moved to the final plugging disposition (11) when the CPA (5) is in the ready-to-lock position (55) and the CPA (5) can be moved to the locking position (65) when the lever (3) is in the final plugging disposition (11) and when the CPA (5) is in the ready-to-lock position. The invention further relates to a connector assembly (7) with the arrangement (1) described above and a mating connector (9).