Electric Cable Coupler Retainer System for Inadvertent Decoupling
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Solution Overview
Problem
The existing electric power cable couplers often experience inadvertent decoupling due to clearance between the male and female counterparts, which can lead to unplugging, especially in critical environments where continuous power is essential.
Innovation Solution
A retainer system is introduced, comprising a female retainer attachable to the female coupler and a male retainer attachable to the male coupler, using prongs and levers to securely engage and prevent accidental disconnection, allowing for easy attachment and secure retention without modifying the existing coupler geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If clearance space is provided between male and female couplers to facilitate insertion, then ease of operation is improved, but reliability deteriorates due to potential inadvertent decoupling
Solution Approach 1:
The coupler is divided into functional segments: the basic coupling mechanism (male plug mass and female recess) and the retention mechanism (retainer arms and engagement features). This segmentation allows the insertion function to operate independently with clearance for ease of operation, while the retention function provides security through positive engagement features that prevent inadvertent decoupling.
Solution Approach 2:
The retainer arms are pre-positioned in a ready-to-engage state before the coupler is fully inserted. As the male coupler is inserted into the female coupler, the retainer arms automatically move into engagement with the retention features, establishing the secure connection before the insertion process is complete. This preliminary action ensures reliability is established during the insertion sequence.
2Reliability
If a retainer system is added to prevent inadvertent decoupling, then reliability is improved, but device complexity increases
Solution Approach 1:
The retention function is merged with the existing coupler structure by integrating retainer arms that are part of the coupler assembly rather than separate components. The retainer arms utilize the same material and manufacturing processes as the coupler body, combining multiple functions (coupling and retention) into a single integrated structure, thereby improving reliability without proportionally increasing device complexity.
Solution Approach 2:
The retainer system is designed to be self-actuating during the insertion process. The retainer arms automatically engage with the retention features as the male coupler is inserted into the female coupler, without requiring separate actuators, motors, or control systems. This self-service mechanism provides reliable retention while minimizing the addition of complex components.
Data Source
AI summary
Male and female couplers which are complementally formed to attach together are fitted with a retainer system including prongs on one of the couplers and a gap on the other of the couplers which can engage the prongs. The prong or gap is configured as either fixed or pivoting so that the pivoting portion can pivot to engage the fixed portion. When the male coupler is inserted into the female coupler, the prongs and gaps engage each other. To remove the male coupler from the female coupler, a pivoting portion must be pivoted to move the gap and prongs away from each other. The gap is configured as an at least partial recess into which the prong is received. The prongs and loop or slit are coupled to the male and female coupler ends through removably attachable male and female retainers or built directly into the female and male coupler.