Deformable Base Cable Plug Array for Mobile Power
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Solution Overview
Problem
The disconnection and reconnection of multiple cable connectors in mobile power generation equipment are time-consuming and challenging, especially due to alignment and force requirements, which delays the setup and operation of the equipment at new locations.
Innovation Solution
A unitized cable plug array with a deformable base and receptacle housing allows for staged coupling of multiple connectors, aligning and spacing the force required for connection, facilitating easier alignment and reduced manual effort by incrementally engaging plugs with receptacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cable connectors are disconnected and reconnected individually, then proper connection can be ensured, but setup and takedown time increases significantly
Solution Approach 1:
The cable connector array is segmented into multiple individual cable connectors (power cables, control cables, data cables) that can be disconnected and reconnected independently. This segmentation allows operators to work on one connector at a time rather than handling all connectors simultaneously, reducing complexity and time while maintaining connection reliability through organized, systematic connection procedures
Solution Approach 2:
The connectors are pre-organized and pre-positioned in a structured array configuration before deployment. Labels, color-coding, and predetermined connection sequences are established in advance, allowing operators to quickly identify and connect cables in the correct order without time-consuming alignment or matching procedures at the connection site
2Productivity
If a large number of cable connectors are coupled simultaneously, then connection speed increases, but alignment difficulty and force requirements increase significantly
Solution Approach 1:
The connector array is divided into multiple independent connector units, each with its own alignment and connection mechanism. This segmentation allows connectors to be engaged in a staged sequence rather than all at once, maintaining connection speed while reducing the alignment complexity and force requirements for each individual connection event
Solution Approach 2:
The connector array incorporates dynamic alignment features such as flexible positioning elements and adaptive alignment mechanisms that adjust during the connection process. This allows the system to accommodate minor misalignments and distribute the connection force dynamically across multiple connectors, making simultaneous coupling feasible without excessive force or precision requirements
3Productivity
If a large number of cable connectors are coupled simultaneously, then connection speed increases, but the force required exceeds manual capability
Solution Approach 1:
The total coupling force requirement is segmented and distributed across multiple independent connector engagements. Instead of requiring all connectors to be coupled simultaneously with high force, the segmented design allows connectors to be engaged in sequences or groups, with each engagement requiring manageable force levels that can be applied manually or with minimal assistance
Solution Approach 2:
The connection process uses periodic or staged engagement of connectors rather than a single simultaneous coupling action. Connectors are engaged in predetermined sequences or groups over time, allowing the force requirement to be distributed across multiple time steps. This periodic action maintains overall connection speed while keeping instantaneous force requirements within manual capability
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 reduces setup and takedown times, simplifies the alignment of multiple connectors, disperses coupling forces, and reduces operator fatigue, enabling faster deployment of mobile power generation equipment.
Implementation Method 1
a deformable base extending along an axis from a first end, through a middle portion and to a second end along a non-linear path
Data Source
AI summary
A system for coupling plugs and receptacles comprises a deformable base extending along an axis from a first end, through a middle portion and to a second end along a non-linear path, first connectors mounted to the base at different axial positions, a housing extending linearly from a third end to a fourth end, second connectors located on the housing at different linear positions, and a closure mechanism configured to deform the base such that each connector of the first connectors aligns with and is couplable to a corresponding connector of the second connectors. A method for coupling plugs and sockets comprises coupling a first plug extending from a base to a first socket located in a housing, aligning a second plug extending from the base with a second socket located in the housing, and flexing the base to bring the second plug into engagement with the second socket.