Electrical Connector System With Morse Taper Locking
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Solution Overview
Problem
Current electrical connector systems require high axial forces and torque for secure connections, leading to complex designs and potential safety issues, especially in applications like aerospace, where fail-safe connections are crucial, and they often suffer from friction corrosion and galling due to lubricant use.
Innovation Solution
An electrical connector system featuring a counter element with an angled outer surface and a lug with a conically shaped connecting element, allowing for low axial force tightening and providing a large contact surface with a Morse taper, enabling secure connections using small fasteners and reducing friction corrosion risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high tightening torque is used to ensure sufficient contact pressure between the cable lug and contact element, then the electrical connection reliability is improved, but the device complexity and risk of damage increase
Solution Approach 1:
The patent applies a curved surface (arc-shaped contact surface) instead of a flat surface for the contact between the cable lug and contact element. This curvature distributes the contact pressure more evenly across the interface, achieving reliable electrical connection with lower tightening torque, thus reducing device complexity and damage risk while maintaining connection reliability.
2Ease of operation
If lubricant is used to reduce friction during nut tightening, then the tightening process is improved, but friction corrosion at contact surfaces increases during service life
Solution Approach 1:
The patent removes the lubricant from the fastening system entirely. By designing the curved contact surface geometry to naturally distribute pressure and reduce friction during tightening, the system achieves ease of operation without lubricant, thereby eliminating the source of friction corrosion during service life.
3Reliability
If a large diameter nut is used to achieve desired torque for high current contact, then the electrical conductivity is improved, but the weight of the connector system increases
Solution Approach 1:
The curved contact surface design enables more efficient force distribution, allowing smaller diameter fasteners to achieve the same contact pressure and electrical conductivity performance. This reduces the mass of the connector system while maintaining reliable electrical connection for high current applications.
4Strength
If threaded fasteners with high torque requirements are used to secure the connection, then the connection strength is improved, but the ease of installation deteriorates
Solution Approach 1:
The arc-shaped contact surface distributes the clamping force uniformly, reducing the peak torque required to achieve secure connection. This allows standard threaded fasteners to provide strong connections with lower, more manageable tightening torques, improving installation ease while maintaining connection strength.
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 system achieves secure, low-resistance connections with reduced axial forces, lightweight design, and fail-safe operation, suitable for high dynamic loads and vibrations, while minimizing the need for lubricants and preventing corrosion.
Implementation Method 1
The inner surface (17a) of the connecting element (17) is angled at the constant angle (α) and exhibits a second circumference (C2) that increases in the direction that points away from the electrical component (12)... the locking device (18) rigidly connects the connecting element (17) with the counter element (13)
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
An electrical connector system 10 for connecting a transmission line 11 with an electrical component 12 includes a counter element 13 that is coupled to the electrical component 12, a lug 15 and a locking device 18. Counter element 13 includes an outer surface 13a and a groove 13c. Lug 15 includes receiving element 16 that receives transmission line 11 and connecting element 17 that has an inner surface 17a. Locking device 18 is attached to the electrical component 12 and rigidly connects the connecting element 17 with the counter element 13.