Connector Contact Pin Centering for Non-Penetrating Continuity Testing
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Solution Overview
Problem
Existing connector testing methods face challenges in maintaining precise alignment and avoiding deformation of lamellar contacts during non-penetrating electrical testing, particularly due to tight manufacturing tolerances and the need for complex contact pin geometries.
Innovation Solution
A single-contact device with a spring-mounted centering aid aligns the contact pin with the connector housing recess before making contact, ensuring non-penetrating electrical connection through a T-shaped head and centering contour that compensates for manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact pin is used for non-penetrating electrical testing of lamellar contacts, then deformation of the lamellar contacts is prevented, but precise alignment and reliable contact are difficult to achieve due to tight manufacturing tolerances
Solution Approach 1:
The centering aid performs preliminary centering action on the housing before the contact pin makes contact with the contact element. The centering aid's centering contour engages with the housing contour in advance, pre-aligning the contact pin with the recess to ensure accurate positioning without requiring tight manufacturing tolerances on the contact pin itself.
Solution Approach 2:
The centering aid acts as an intermediary element between the contact pin and the housing. It transfers the centering function from the contact pin to a dedicated component, allowing the contact pin to focus solely on making reliable electrical contact while the centering aid handles the alignment task through its centering contour.
2Ease of manufacture
If the contact pin geometry is simplified for ease of manufacture, then manufacturing complexity is reduced, but alignment accuracy with the connector recess deteriorates
Solution Approach 1:
The centering function is extracted from the contact pin geometry and transferred to a separate centering aid. This allows the contact pin to have a simple, easy-to-manufacture cylindrical shape without requiring complex geometric features for alignment, while the centering aid carries the alignment function through its centering contour.
Solution Approach 2:
The contacting device is segmented into two functional components: a simple contact pin for electrical contact and a separate centering aid for alignment. This segmentation allows each component to be optimized independently - the contact pin for ease of manufacture and the centering aid for alignment accuracy.
3Manufacturing precision
If manufacturing tolerances are tightened to improve alignment accuracy, then alignment precision is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention changes the geometric parameters of the centering aid, specifically providing a centering contour with a larger radius than the recess radius. This parameter change allows the centering aid to engage the housing contour in a way that is less sensitive to manufacturing tolerances, achieving good alignment without requiring tight tolerances on the housing features.
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 reliable electrical contact by aligning the contact pin accurately with the connector recess, minimizing deformation and loose connections, thereby improving testing efficiency and compliance with manufacturer specifications.
Implementation Method 1
a leading centering aid for the contact pin, wherein the contact pin is electrically conductive and spring-mounted in one placement direction, and the centering aid is movably spring-mounted coaxially to the contact pin
Implementation Method 2
the centering aid first places onto a housing of the connector, centers itself on the housing, and thereby aligns the contact pin with a recess in the housing
Data Source
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AI summary
The present invention relates to an individually contacting apparatus (100) for a testing device (500) for testing the continuity of a connector (200), wherein the individually contacting apparatus (100) has a contact pin (102) to be placed onto a connector (200) contact element (400) to be contacted, and a leading centering aid (104) for the contact pin (102), wherein the contact pin (102) is electrically conductively spring-mounted in an attachment direction, and the centering aid (104) is spring-mounted so as to be movable coaxially with the contact pin (102).