Electric Coupler Vibration Damping via Elastic Ring Element
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Solution Overview
Problem
Existing electrical connections in vehicles, particularly those near high-frequency vibrating units like turbochargers, experience increased wear and conductivity issues due to vibrations, which prior solutions like elastic seals and minimal play designs do not adequately address.
Innovation Solution
An electrical connecting line featuring a plug housing with a tubular insertion area and a ring element that surrounds the electrical line, combined with an elastic sealing element and a cap, which reduces vibration propagation by eliminating play and maintaining a mechanical connection through inclined guide surfaces and a flexible ring element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If elastic sealing elements and minimal clearance designs are used, then moisture protection is improved, but vibration-induced wear and contact problems worsen
Solution Approach 1:
A damping element is introduced as an intermediary component between the cable and the contact element. This damping element absorbs vibrations before they reach the contact element, preventing vibration-induced wear and contact problems while maintaining the minimal clearance design for moisture protection.
Solution Approach 2:
The damping element is positioned in advance between the cable and contact element to cushion against upcoming vibrations. This prior cushioning prevents direct transmission of high-frequency vibrations from the cable to the contact element, ensuring reliable electrical connection under vibrational conditions.
2Stability of the object's composition
If clamping ribs are added to prevent movement, then connection stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
A damping element in the form of a flexible ring or collar is used instead of rigid clamping ribs. This flexible element provides the necessary stabilization and vibration damping while maintaining a simpler structure that is easier to manufacture and assemble compared to complex clamping rib systems.
3Manufacturing precision
If minimal clearance is used between contact elements and cable, then assembly precision is improved, but vibration-induced wear worsens
Solution Approach 1:
The damping element serves as a mediator between the cable and contact element, allowing minimal clearance for precise assembly while preventing direct vibration transmission. This intermediary component absorbs vibrational energy, preventing wear on the contact elements despite the tight clearance design.
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 design significantly reduces wear on contact elements, enhances the reliability and service life of electrical connections, and can be produced inexpensively using standard facilities, effectively addressing the challenges of high-frequency vibrations.
Implementation Method 1
an elastic sealing element, wherein the sealing element is elastically deformed between the cap and the ring element and thereby generates the necessary force to press the ring element towards the contact element
Data Source
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AI summary
Electrical connecting cable (10) comprising a connector housing (100), an electrical cable (20), a ring element (40), an elastic sealing element (60), and a cap (80), wherein the connector housing (100) has a tubular insertion area (102) for inserting the electrical cable (20) into the connector housing (100), wherein the insertion area (102) is aligned along a longitudinal axis (X) of the electrical cable (20) and has a constriction (104), the cap (80) is attached to the connector housing (100) by retaining means, the cap (80) has an opening (82) for passing the electrical cable (20), wherein the ring element (40) at least partially surrounds the electrical cable and the sealing element (60) surrounds the electrical cable, wherein the ring element (40) and the sealing element (60) are arranged between the constriction (104) and the cap (80).