Electrical Connector Rotating Locking Bolt Sequence Control
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Solution Overview
Problem
Existing electrical connectors for high-load and low-load connections face issues with complex and costly mechanisms for controlling connection sequences, leading to potential hazards and difficulties in recognizing faults, and are expensive to manufacture and assemble, especially when multiple connections are required.
Innovation Solution
A simplified electrical connector design featuring a rotatable locking bolt that prevents low-load connections until high-load connections are complete and ensures separation only when de-energized, with high-load contact elements in chambers for insulation and a power control circuit to manage connections via a relay or electronic load switch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex mechanism is used to control the mobility of the low-load housing part as a function of the connection status, then the chronological sequence of connections is ensured, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the complex control mechanism from the connector and replaces it with a simple mechanical blocking element (the slider) that passively enforces the connection sequence through its position relative to the locking bolt, thereby reducing device complexity while maintaining chronological sequence control
Solution Approach 2:
The slider acts as an intermediary element between the high-load and low-load connection components, using its physical position to mediate the connection sequence by blocking or allowing access to the locking mechanism based on whether the high-load connection is established
2Reliability
If a complex mechanism is used to control the mobility of the low-load housing part, then the connection sequence is controlled, but the ease of detecting faults deteriorates
Solution Approach 1:
While not using actual color changes, the patent applies the principle of visual indication by making the slider's position (which indicates connection status) externally visible and accessible, allowing operators to easily detect the state of the connector and any faults in its operation
Solution Approach 2:
By removing the complex internal mechanism and replacing it with the simple, externally accessible slider, the patent makes the connection status and potential faults immediately visible and detectable from the outside, improving fault detectability
3Adaptability or versatility
If several lever switches are provided for multiple power connections, then the connection control is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies universality by designing a single locking mechanism with a slider that can control multiple power connections simultaneously, rather than requiring separate lever switches for each connection, thereby reducing complexity while maintaining the ability to handle multiple power connections
Solution Approach 2:
The patent merges multiple connection control functions into a single integrated locking mechanism where the slider's position controls the state of all high-load and low-load connections simultaneously, reducing the number of separate components and simplifying the overall structure
4Adaptability or versatility
If the electrical connector is arranged at the end point of the leads, then the high-load and low-load connections are made, but the ease of assembly and integration into cable harnesses deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the connector into distinct high-load and low-load housing parts that can be independently assembled and then joined together, allowing for easier integration into cable harnesses and more flexible assembly processes compared to a monolithic end-point connector design
Data Source
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Figure 5~6
AI summary
The connector has plug connector parts, which are joined together, where the plug connector parts consist of a high load housing part (3a) for high load contact units and a low load housing part (4a) for low load contact units. The contact units are arranged parallel to one another and connected with one another in an axial direction. The low load housing part is designed integrally with the high load housing part.