Vibration-Resistant Current Connector With Cutting Edge Contact Spring
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Solution Overview
Problem
Electrical connections in automatic transmission systems of motor vehicles are prone to malfunction due to vibrations, leading to unreliable contact between the actuator and the circuit arrangement, particularly between the contact spring wires and the printed circuit board.
Innovation Solution
The design incorporates a contact spring wire with a spring-loaded end contact featuring cutting edges that anchor into a contact pad on the printed circuit board, ensuring a secure and vibration-resistant connection through a spring pressure contact, utilizing materials like stainless steel or copper alloys for durability and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spring pressure contact is used between the contact spring wire and the contact point, then the electrical connection reliability is improved, but the contact may still slip or lose contact under vibration conditions
Solution Approach 1:
The contact spring wire is pre-formed with a cutting edge at its end contact area before assembly. This preliminary geometric modification enables the contact to actively engage with the contact point by digging into its surface, creating a positive mechanical interlock that prevents slippage under vibration while maintaining reliable electrical connection
Solution Approach 2:
The cutting edge is created only at the specific contact area of the end contact, while the rest of the spring wire maintains its elastic properties. This localized geometric modification concentrates the anchoring function at the contact interface without compromising the overall spring functionality and electrical conductivity
2Reliability
If the contact spring wire is designed with high spring force to ensure continuous contact, then the electrical connection reliability is improved, but the contact point may deform or damage under excessive pressure
Solution Approach 1:
The cutting edge is pre-formed on the contact spring wire to enable immediate mechanical interlocking with the contact point upon assembly. This preliminary geometric feature ensures that the anchoring effect is established before any vibration or operational stress occurs, preventing slippage without requiring excessive spring force that could damage the contact point
Solution Approach 2:
The cutting edge intentionally creates a localized deformation or anchoring effect in the contact point material during assembly. This controlled 'damage' or penetration creates a mechanical interlock that actually strengthens the connection, converting the potential harm of material deformation into a beneficial anchoring mechanism that prevents contact loss under vibration
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 provides a reliable and continuous electrical connection, preventing relative movement between contacts during vibrations and ensuring the stability of control commands for automatic transmission systems.
Implementation Method 1
the spring force necessary for the contact pressure is applied via the design of the contact spring wire as a spring element
Implementation Method 2
at least one cutting edge is arranged at the end contact of the contact spring wire, also referred to as a contact bracket, in the area of the contact surface, which is in engagement with the contact point, i.e., the at least one cutting edge digs into the surface of the contact point during the establishment of the electrical connection, which results in an anchoring of the cutting edge
Data Source
AI summary
An arrangement for electrical contacting of a current connector (3) with a circuit arrangement (1) is provided. The current connector (3) includes at least one contact spring wire (5, 6) with an end contact (5a, 6a), which is configured for spring-loading, and the circuit arrangement (1) includes at least one contact point. The end contact (5a, 6a) and the contact point each form a spring pressure contact, and the end contact (5a, 6a) of the contact spring wire (5, 6) is configured as a bracket with an outer contact surface and at least one cutting edge arranged proximate the contact surface, which is engaged with the contact point.