Elastic Plug Holder for Consistent Insertion Force
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Solution Overview
Problem
Conventional connection devices for sensors in automotive applications face challenges in mechanically decoupling the sensor plug from the cable gland without transferring vibrations, which can interfere with measurement signals and complicate the assembly process, making it difficult to automate.
Innovation Solution
A connection device featuring an elastic plug holder that compensates for varying distances between the plug and mating plug, ensuring a consistent insertion force and complete mechanical decoupling by retracting the plug holder after insertion, with a locking mechanism to prevent accidental re-engagement and a funnel-shaped mating connector for easy alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor connector is manually disconnected from the cable gland during installation, then the mechanical decoupling is achieved, but the installation process becomes time-consuming and difficult to automate
Solution Approach 1:
The connector holder is designed to automatically release the sensor connector from the cable gland through its own elastic deformation when pulled in the insertion direction, without requiring manual intervention or additional tools. The elastic arms naturally return to their original position, achieving self-service mechanical decoupling
Solution Approach 2:
The connector holder transitions from a static holding position to a dynamic retraction motion, allowing the sensor connector to be pulled through the cable gland opening and mechanically decoupled automatically during the insertion process
2Ease of operation
If a holder rotation mechanism is used to release the sensor connector, then the connector can be detached, but the installation space requirement increases and vibration transmission occurs
Solution Approach 1:
The connector holder is segmented into multiple elastic arms that can independently deform and return, allowing the sensor connector to be released through linear pulling motion rather than rotation, reducing the required installation space
Solution Approach 2:
Instead of rotating the holder to release the connector, the design inverts the mechanism by pulling the holder in the insertion direction to achieve release, eliminating the need for rotation and reducing space requirements
3Stability of the object's composition
If the plug holder is rigid, then the structural stability is high, but the insertion force varies with distance changes causing connection quality issues
Solution Approach 1:
The plug holder material or structure is changed to exhibit elastic properties, allowing it to deform and compensate for distance variations between the plug and mating plug, ensuring consistent insertion force and connection quality while maintaining structural stability
Solution Approach 2:
The plug holder is designed with flexible elastic arms that can bend and adapt to position variations, providing both structural stability and tolerance for distance changes, ensuring reliable electrical connection
4Reliability
If the plug holder exerts high insertion force, then the electrical connection is secure, but the plug or mating plug may be damaged
Solution Approach 1:
The elastic plug holder is designed to provide controlled insertion force that is sufficient to ensure reliable electrical connection while inherently limiting the maximum force to prevent damage to the plug or mating plug, acting as a cushioning mechanism
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 ensures reliable and consistent electrical connections, reduces the risk of damage from uneven forces, simplifies automation, and effectively prevents vibration transmission to the sensor plug, enhancing operational reliability and assembly efficiency.
Implementation Method 1
The plug holder is elastically designed in the insertion direction of the plug. The elastic plug holder ensures that even with varying distances between the plug and the mating plug, a substantially unchanged insertion force is always exerted, because the plug holder can compensate for the different distances.
Implementation Method 2
effectively prevents vibration transmission to the sensor plug, enhancing operational reliability and assembly efficiency
Data Source
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AI summary
A connector device with a plug is proposed, designed to establish an electrical connection with a mating plug. The connector device features a cable entry point and a plug holder in which the plug is detachably secured. The plug holder is elastically designed in the insertion direction of the plug. This elasticity ensures that even with varying distances between the plug and the mating plug, a substantially constant insertion force is exerted, as the plug holder can compensate for these differences. A consistent insertion force prevents damage to the plug or the mating plug and ensures a consistent quality of the connection.