Bolt-Fastened Connector Structure for Misalignment and Co-Rotation
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Solution Overview
Problem
Existing connectors with rod-shaped terminals face challenges in preventing co-rotation while maintaining workability, especially when there is axial misalignment or inclination between the male and female terminals, leading to increased insertion force and impaired connection efficiency.
Innovation Solution
The connector design incorporates a rotation restricting portion on the terminal and a housing with an inclined inner wall, allowing the terminal to swing and adjust during assembly, reducing the insertion force by enabling easy alignment and preventing co-rotation through a gap mechanism that facilitates proper bolting and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the male terminal is firmly fixed to the terminal block via the connection socket, then co-rotation and inclination are prevented, but the insertion force increases due to frictional force when axial misalignment or inclination occurs between terminals
Solution Approach 1:
The terminal is designed with a rotation restricting portion that can dynamically adjust its state. During insertion, the terminal body can rotate slightly within the connection socket to accommodate misalignment, reducing insertion force. After insertion, the rotation restricting portion engages to prevent co-rotation, ensuring stable electrical connection. This dynamic behavior resolves the contradiction between allowing movement during insertion and preventing movement during operation.
Solution Approach 2:
The frictional force between the terminal and connection socket is controlled by changing the friction coefficient through surface treatment or material selection. By optimizing the friction characteristics, the connection provides sufficient grip to prevent co-rotation while allowing enough slip during insertion to accommodate misalignment, thereby reducing insertion force. This parameter adjustment resolves the contradiction between firm fixation and easy insertion.
2Stability of the object's composition
If the connection socket is sufficiently firmly fixed to the terminal block, then rotation of the connection socket and male terminal is prevented, but the workability deteriorates when axial misalignment or inclination occurs during connection
Solution Approach 1:
The connection socket is designed with a rotation restricting portion that remains engaged with the terminal body during operation to prevent rotation, but allows controlled movement during the insertion process. This enables the terminal to self-align through slight rotations, improving workability while maintaining rotation prevention during stable connection.
Solution Approach 2:
The rotation restricting portion acts as an intermediary mechanism between the connection socket and terminal block. It provides rotation prevention through engagement with the terminal body while allowing the necessary flexibility during insertion to accommodate misalignment. This intermediary structure resolves the contradiction between firm fixation and ease of operation.
3Stability of the object's composition
If the male terminal is bolted to the connection socket, then co-rotation is prevented, but insertion force increases due to frictional force when misalignment occurs
Solution Approach 1:
The terminal body is designed to rotate slightly within the connection socket during insertion to accommodate misalignment, reducing frictional force and insertion force. After insertion, the rotation restricting portion engages to prevent co-rotation. This dynamic behavior during the insertion process resolves the contradiction between preventing co-rotation and reducing insertion force.
Solution Approach 2:
The friction coefficient between the terminal body and connection socket is optimized through material selection or surface treatment. By controlling the friction characteristics, the system allows sufficient movement during insertion to reduce insertion force while providing adequate grip after insertion to prevent co-rotation. This parameter optimization resolves the contradiction between co-rotation prevention and insertion force reduction.
Data Source
AI summary
A connector includes: a rod-shaped terminal; and a housing having a terminal accommodating chamber configured to accommodate the terminal. The terminal has: a rotation restricting portion configured to engage with an inner wall of the terminal accommodating chamber to restrict rotation of the terminal about an axis of the terminal; a contact configured to be electrically connected to a counterpart terminal; and a hole configured to allow a bolt to be screwed into the hole about the axis. The housing has: a holding portion that holds the terminal inside the terminal accommodating chamber; and an opening configured to expose the hole of the terminal to an outside of the terminal accommodating chamber. The connector is configured to have a gap between the inner wall of the terminal accommodating chamber and the terminal, the gap increasing from the rotation restricting portion of the terminal toward the opening of the housing.