Modular Controller Connector With Side-Access Spring Contacts
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Solution Overview
Problem
Existing electrical connectors for controllers and devices often require complex wiring and reconfiguration, making it difficult to efficiently connect and disconnect devices without disturbing adjacent components, especially in automation and process control systems.
Innovation Solution
The development of an electrical connector system featuring spring contacts and terminal pins housed within a modular housing, allowing for easy alignment and connection of devices through accessible sides, with conductive bridges and terminal receiving slots for secure electrical coupling, facilitating flexible and efficient device coupling without requiring extensive reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wiring and reconfiguration methods are used to connect devices, then electrical connections can be established, but the process becomes complex and time-consuming, requiring disturbance of adjacent components
Solution Approach 1:
The electrical connector is divided into separate modular components: a housing with spring contacts, terminal pins, and conductive bridges. Each component can be independently assembled and connected, allowing devices to be linked through simple modular coupling rather than complex wiring. The spring contacts and terminal pins are segmented to engage with corresponding elements on adjacent devices, enabling straightforward connection without disturbing other components.
Solution Approach 2:
The terminal receiving slots are formed within the housing structure, creating a nested arrangement where terminal pins insert into recessed slots. The conductive bridges are housed within the housing, and spring contacts are positioned within designated spaces. This nested configuration allows compact integration of multiple electrical connection elements, reducing overall complexity while maintaining connection functionality.
2Productivity
If devices are connected using existing electrical connectors, then electrical coupling is achieved, but installation and replacement require extensive reconfiguration and time
Solution Approach 1:
The housing is pre-formed with terminal receiving slots and conductive bridges positioned in advance. Spring contacts are pre-assembled within the housing structure with their arms and connecting elements already in place. This preliminary preparation eliminates the need for complex on-site assembly or reconfiguration during installation, allowing devices to be quickly connected by simply engaging the pre-configured connector elements.
Solution Approach 2:
The spring contacts incorporate flexible arms that can dynamically adjust during connection and disconnection. The spring mechanism allows the contacts to flex and engage with terminal pins automatically, reducing the precision and time required for manual alignment. This dynamic flexibility enables rapid connection without extensive reconfiguration, improving installation speed while maintaining reliable electrical coupling.
3Adaptability or versatility
If modular spring contacts and terminal pins are used, then device replacement becomes easier, but the connector structure becomes more complex
Solution Approach 1:
The spring contacts and terminal pins are merged into a single integrated housing structure. The conductive bridges connect the spring contacts to the terminal pins, creating a unified assembly where multiple functional elements are combined. This merging reduces the number of separate components that need to be handled during device replacement, improving adaptability while managing structural complexity through integration rather than proliferation of parts.
Solution Approach 2:
The housing design incorporates both spring contacts and terminal pins within the same structure, allowing the connector to serve multiple functions: providing both flexible spring-based connections and rigid terminal pin connections. The conductive bridges enable electrical coupling between these different contact types. This multi-functionality allows the same connector structure to accommodate various connection scenarios, enhancing device replaceability without requiring multiple specialized components.
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
This solution enables quick and secure electrical connections between controllers and devices, allowing for easy replacement or addition of devices without disturbing adjacent components, improving system flexibility and reducing installation complexity.
Implementation Method 1
The first spring contact may extend outside of the housing and may be accessible from the first side of the housing and the second spring contact may extend outside of the housing and may be accessible from the second opposing side of the housing. When a controller with a similar electrical connector is placed next to the first side or the second side, the spring contacts may electrically connect.
Data Source
AI summary
An electronic device including a plurality of ports for electrically connecting the device to another device. The electronic device may include a housing including a front, a back and at least a first side and an opposing second side extending between the front and the back, a printed circuit board housed by the housing, and an electrical connector electrically connected to the printed circuit board. The electrical connector may include a first spring contact, a second spring contact, and an electrically conductive bridge mechanically and electrically connecting the first spring contact and the second spring contact. The electrically conductive bridge may be housed by the housing. The first and second spring contacts may extend outside of the housing and may be accessible from the first and second sides of the housing, respectively.