Electromagnetic Connector Coupling for Low-Force Reliable Mating
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Solution Overview
Problem
Existing electrical connectors require varying amounts of force to mate and unmate, which can lead to unreliable connections, especially under conditions of vibration or temperature changes, and may require mechanical fit that degrades over time.
Innovation Solution
An electrical connector system utilizing an electromagnet to assist in mating and unmating by applying a magnetic force between a first electrical connector with an electromagnet and a second electrical connector with a magnetic element, controlled by a proximity detector and input device to ensure secure coupling and easy separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical force is used to mate connectors, then electrical connection is established, but varying amounts of force are needed depending on pin and socket design which affects reliability
Solution Approach 1:
The patent replaces the traditional mechanical force-based connection system with a magnetic field-based system. An electromagnet generates a magnetic field that acts on a magnetic element in the mating connector, providing a consistent and controllable attractive force that eliminates the variability associated with mechanical pin-and-socket designs. This substitution resolves the contradiction by providing reliable connection without dependence on varying mechanical forces.
Solution Approach 2:
The patent changes the fundamental parameter of connection force from mechanical to magnetic. By controlling the electrical current to the electromagnet, the magnetic field strength can be precisely adjusted to provide optimal mating force. This parameter change allows for consistent and reliable connection establishment without the variability inherent in mechanical systems.
2Reliability
If friction or mechanical fit is used between pins and sockets, then connection is maintained, but reliability decreases over time under vibration, temperature changes, or relative movement
Solution Approach 1:
The patent replaces the friction-based mechanical fit system with a magnetic field-based holding system. The electromagnet continuously generates a magnetic field that maintains the connection between connectors, eliminating the degradation issues associated with mechanical wear, vibration, and thermal expansion. This substitution resolves the contradiction by providing stable connection maintenance over extended periods and under varying environmental conditions.
Solution Approach 2:
The patent implements continuous magnetic field generation to maintain the connection. As long as electrical power is supplied to the electromagnet, the magnetic field continuously acts on the magnetic element, providing ongoing holding force that does not degrade over time. This continuous action resolves the contradiction by ensuring connection stability throughout the operational lifetime of the system.
3Force
If electromagnetic force is used to attract connectors, then mating force is reduced, but additional components (electromagnet, control circuit) are added
Solution Approach 1:
The patent integrates the electromagnet and magnetic element as additional components that provide multiple functions: they generate the attractive force for mating, maintain the connection during operation, and can be controlled to facilitate easy unmating. This multi-functionality resolves the contradiction by justifying the added complexity through the achievement of reduced mating force and improved connection reliability simultaneously.
4Reliability
If magnetic force is used to hold connectors together, then secure connection is achieved, but ease of separation is reduced
Solution Approach 1:
The patent implements a dynamic control system where the electrical current to the electromagnet can be adjusted or interrupted. During normal operation, full current provides strong magnetic holding force for secure connection. For unmating, the current can be reduced or interrupted, weakening or eliminating the magnetic force to facilitate easy separation. This dynamic control resolves the contradiction by providing both secure connection and easy unmating through electrical control.
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
The system reduces the force required for connector mating and unmate, enhances reliability by using magnetic attraction, and maintains a secure connection while allowing easy separation, minimizing damage and ensuring consistent performance across different conditions.
Implementation Method 1
an electromagnet on the first electrical connector adapted to produce a magnetic force that acts on a magnetic element on the second electrical connector
Data Source
AI summary
An electrical connector system for assisting in coupling and unmating electrical connectors. The system generally includes an electromagnet to assist in mating and, alternatively, unmating or uncoupling a first electrical connector with a second electrical connector. The system may include a first electrical connector having a first plurality of contacts, an electromagnet on the first electrical connector adapted to produce a magnetic force, and an input device adapted to receive an input and to provide an output that causes an electrical current to be supplied to the electromagnet. When coupled, the first plurality of electrical contacts are conductively engaged with a second plurality of electrical contacts on the second electrical connector.