Electrical Connector Locking Feature for Pre-Staged Safety
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Solution Overview
Problem
Traditional connector systems lack a mechanism to securely lock the connector bodies in a pre-staged position with disconnected electrical terminals, preventing unintentional movement to a staged position, which poses safety risks, especially in high voltage applications.
Innovation Solution
The electrical connector system incorporates a locking feature with a flexible lock arm and a lock-out mechanism that secures the connector bodies in a pre-staged position and allows secure transition to a staged position only after disengagement, utilizing a shunt connector for electrical interconnection and a lock-out feature to prevent unintended movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional connector designs are used with minimal engagement force, then ease of operation is improved, but safety is worsened due to risk of unintentional movement between pre-staged and staged positions
Solution Approach 1:
The lock arm is designed as a movable component that can transition between locked and unlocked positions. It pivotably engages with the lock tab to prevent unintentional movement, yet can be deliberately actuated to allow position changes. This dynamic mechanism maintains safety while permitting controlled operation.
Solution Approach 2:
The locking feature is designed to automatically engage when the connector bodies are mated in the pre-staged position, preventing unintentional movement before electrical connection is intended. This preliminary protective action occurs automatically upon mating, blocking harmful unintended movements.
2Reliability
If a locking mechanism is added to prevent unintentional movement, then safety is improved, but device complexity increases
Solution Approach 1:
The lock arm serves multiple functions: it locks the connector in the pre-staged position to prevent unintentional movement, and it also serves as a visual indicator of the connector's operational state. The resilient U-shaped strap provides both locking force and return spring function. By combining multiple functions into single components, the design achieves safety without proportionally increasing complexity.
Solution Approach 2:
The locking feature is integrated into the connector body structure rather than being a separate assembly. The lock tab is defined by the first connector body itself, and the lock arm is pivotably attached to the second connector body, merging the locking function into the existing connector structures.
3Ease of operation
If the connector allows easy movement between positions, then ease of operation is improved, but reliability is worsened due to risk of unintended energization
Solution Approach 1:
The locking feature automatically engages when the connector bodies are mated in the pre-staged position, preventing any movement that would cause unintended energization. This preliminary protective action occurs before any operational movement is attempted, blocking harmful unintended movements while allowing deliberate controlled transitions.
Solution Approach 2:
The lock arm provides a dynamic locking mechanism that can be deliberately actuated to release. This allows easy controlled movement when intended, while preventing easy unintended movement. The resilience of the U-shaped strap enables smooth, controlled transitions rather than abrupt movements.
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 ensures operator safety by preventing unintentional energization of high voltage circuits by requiring a deliberate secondary operation to transition between pre-staged and staged positions, ensuring secure electrical connectivity and disconnection.
Implementation Method 1
a flexible lock arm pivotably attached to the second connector body by a resilient U-shaped strap
Data Source
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AI summary
An electrical connector system (10) is presented herein. The electrical connector system (10) includes a first connector body (12) containing a first plurality of terminals and a second connector body (14) containing a second plurality of terminals that are configured to interconnect with the first plurality of terminals. The second connector body (14) is configured to receive the first connector body (12). The electrical connector system (10) further includes a locking feature (16) configured to secure the first connector body (12) to the second connector body (14) in a pre-staged position (18) in which the first plurality of terminals is not connected to the second plurality of terminals and further configured to secure the first connector body (12) to the second connector body (14) in a staged position (20) in which the first plurality of terminals is connected to the second plurality of terminals after disengaging the locking feature (16) in the pre-staged position (18).