Connector Locking Tab Test Path for Secondary Lock Verification
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Solution Overview
Problem
Existing plug connectors face difficulties in determining whether the secondary locking tab has moved into its final locking position, which is crucial for preventing damage from external stresses like temperature and vibration, especially in the vehicle sector.
Innovation Solution
A plug connector design with a test pin system that allows insertion and withdrawal, where the test pin's path length indicates whether the locking tab is in its pre-locking or final locking position, and additional free space on both sides enhances testability and safety, ensuring the tab is fully engaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secondary locking mechanism is added to prevent contact partner removal, then reliability is improved, but device complexity increases
Solution Approach 1:
The locking tab is integrated directly into the contact carrier as a single piece, merging the locking mechanism with the contact carrier structure. This eliminates the need for separate locking components while maintaining the secondary locking function, thus improving reliability without proportionally increasing device complexity.
Solution Approach 2:
The locking tab automatically performs the locking function through its own pivoting motion without requiring additional actuators or complex control mechanisms. The tab's geometric design enables it to self-lock the contact partner through mechanical interference, reducing overall system complexity while ensuring reliable locking.
2Productivity
If the locking tab extends over multiple contact chambers to engage several contact partners, then productivity is improved, but the locking tab may deflect and cannot be guaranteed to be fully engaged
Solution Approach 1:
The locking tab is designed with predetermined pivot paths and geometric constraints that guide it through defined positions during the locking process. The tab's movement is pre-configured to ensure proper engagement sequence, allowing simultaneous engagement of multiple contact partners while maintaining reliable positioning through built-in geometric guidance.
Solution Approach 2:
The patent replaces complex mechanical guidance systems with a simplified pivoting mechanism that relies on geometric constraints and mechanical interference. The locking tab's rotation is constrained by the contact carrier geometry and contact partner positions, eliminating the need for additional guidance mechanisms while ensuring reliable engagement across multiple contact chambers.
3Measurement precision
If clearances are provided on both sides of the locking tab for testing, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The testing functionality is extracted as a separate, simple operation using an external test pin rather than integrating complex sensors or measurement systems into the connector. The clearances provide access for the external test tool, allowing position verification without adding measurement components to the connector structure itself, thus maintaining simplicity while enabling precise measurement.
Data Source
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AI summary
Method for testing a connector for a plug connection, comprising a contact carrier (1) with at least one contact chamber (2) receiving a contact partner, wherein the contact partner is inserted in its contact chamber (2) in a primary locking manner, wherein a locking tab (3) is pivotably arranged on the contact carrier (1) with its mounting end (9) and forms a secondary locking mechanism for the at least one contact partner when it is inserted in a primary locking manner in its contact chamber (2), characterized in that the locking tab (3) has at its end facing away from the mounting end (9) a transverse web (4) which, together with the contact carrier (1), forms the secondary locking mechanism, wherein the transverse web (4) has at least one projection (6) which extends beyond a side edge (7) of the locking tab (3) and forms a clearance (6).wherein a test pin (5) is inserted into the free space (6) and its test path (10) is recorded, wherein the test path (10) is influenced by the projection (6) depending on the position of the locking tab (3).