Electrical Connector Assembly Vibration Locking Mechanism
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Solution Overview
Problem
Electrical connector assemblies in the automotive industry face issues with connectors becoming unmated due to vibrations, leading to potential disconnection and improper mating.
Innovation Solution
The design incorporates a male connector, a female connector with a flex arm and nib, and a sleeve with an inner surface that overlaps the flex arm, forcing engagement between the shoulder and nib to prevent relative movement and maintain connection during vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a male connector and female connector are mated together to join electrical circuits, then the electrical connection is established, but the connectors become unmated due to vibration and other causes
Solution Approach 1:
A sleeve is introduced as an intermediary component between the male and female connectors. The sleeve includes a locking mechanism with a movable locking element that actively engages with both connectors to maintain their mated position, preventing separation due to vibration or other external forces
Solution Approach 2:
The locking mechanism incorporates a movable locking element that can dynamically adjust and engage with the male and female connectors. This dynamic component allows the system to adapt to vibrational forces while maintaining stable connection, rather than relying on static rigid fixation
2Reliability
If the connectors are designed with simple mating structures, then the device complexity is reduced, but the connectors cannot maintain engagement under vibration
Solution Approach 1:
The connector assembly is segmented into distinct functional components: the male connector, female connector, and sleeve with locking mechanism. This segmentation allows each component to perform its specific function while working together to provide vibration resistance, balancing complexity with performance
3Stability of the object's composition
If the sleeve overlaps the flex arm to force engagement between shoulder and nib, then relative movement is eliminated, but the manufacturing precision requirements increase
Solution Approach 1:
The design utilizes the flexibility parameter of the flex arm to accommodate variations in manufacturing precision. The flex arm can bend and adjust its position within the sleeve, allowing the shoulder and nib to engage properly even with minor dimensional variations, thereby reducing the stringency of manufacturing precision requirements
Data Source
AI summary
An electrical connector assembly includes a male connector, a female connector, and a sleeve. The male connector has a shoulder. The female connector is constructed to receive the male connector and has a flex arm with a nib. The sleeve is constructed to receive the female connector and has an inner surface. When the male connector, the female connector, and the sleeve are telescoped together, the inner surface of the sleeve overlaps the flex arm and forces engagement between the shoulder and the nib to eliminate relative movement between the male and female connectors.