Controller Unit Module Asymmetry Prevention
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Solution Overview
Problem
Existing methods for preventing wrong attachment of modules to a base unit in controller units are inadequate, as they may allow incorrect modules to be fitted, potentially causing damage due to improper electrical connections and excessive force during the mounting process.
Innovation Solution
A controller unit design featuring a base unit with a recess and a module with a projection, where the positional relationship between the recess and projection prevents incorrect module attachment by hindering further turning when a wrong module is attempted to be mounted, ensuring only correct modules can be electrically connected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If modules are mounted by linearly pressing connectors together, then the mounting process is simple, but wrong modules may be fitted causing electrical failure
Solution Approach 1:
The patent applies asymmetry by providing a projection on one module and a corresponding recess on another module, creating an asymmetric mechanical interface. This asymmetric structure allows only modules of correct types to be fitted together, preventing wrong attachments while maintaining a simple mounting process. The projection and recess geometry ensures that incompatible modules cannot be mechanically connected.
2Ease of operation
If modules are turned to join connectors, then connection is achieved, but wrong modules may still be fitted causing connector damage
Solution Approach 1:
The patent applies preliminary action by providing the projection and recess structure before the connectors are brought into contact. This preliminary mechanical interface ensures that only correctly matched modules can be turned and connected. The projection must align with the recess before turning can occur, preventing wrong modules from being rotated and connected, thereby avoiding connector damage.
3Volume of moving object
If connectors are positioned close together for compact design, then space efficiency improves, but wrong module attachment becomes more likely
Solution Approach 1:
The patent applies dimensionality change by introducing a mechanical interlocking dimension (the projection-recess relationship) in addition to the electrical connection dimension. This additional dimensional constraint ensures that even when connectors are positioned close together for compactness, wrong modules cannot be attached because the projection and recess geometries must match. This allows compact design while maintaining reliable module type discrimination.
Data Source
AI summary
A controller unit includes: a base unit having a slot; a module that includes a printed circuit board and that is mounted on the base unit; a pair of male and female connectors, one being included in the base unit and the other being included in the module; and a turning support that allows the module to be turned with respect to the base unit. A pair of a recess and a projection are provided to prevent wrong attachment. The base unit has one of the recess and the projection and the module has the other. The positions of the recess and the projection vary depending on the type of module.