Vibration Protection for Screw Couplings via Flexible Lamella
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Solution Overview
Problem
Existing vibration protection solutions for screw-locked plug connections in harsh industrial environments face challenges such as increased complexity, cost, and reduced compactness due to the use of additional parts or high rigidity elements, leading to poor haptics and reproducibility, and are prone to wear and functional failures under dynamic loads.
Innovation Solution
A vibration-protected plug connection design without additional parts, utilizing a one-piece contact carrier made of insulating material with axial stop surfaces and a radially deflectable flexible lamella, where the lamella's orientation ensures tangential alignment of force components, preventing undesirable deformations and maintaining resilience, and featuring a convexly curved projection interacting with the threaded part's toothing to achieve a well-defined and reproducible torque curve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional parts are used for vibration protection, then vibration protection is improved, but device complexity increases
Solution Approach 1:
The vibration protection function is merged into the contact carrier itself through the flexible lamella, eliminating the need for separate vibration protection parts. The lamella is integrally formed with the contact carrier body, combining sealing and vibration protection functions in a single component.
Solution Approach 2:
The flexible lamella provides self-service vibration protection through its inherent elasticity and radial deflection capability. The lamella automatically generates the necessary wave-like moment curve during screw rotation without requiring additional active components or complex mechanisms.
2Reliability
If additional parts are used for vibration protection, then vibration protection is improved, but manufacturing cost increases
Solution Approach 1:
The flexible lamella is integrally formed with the contact carrier in a single injection molding process, eliminating the need for separate manufacturing steps and assembly operations for additional vibration protection parts, thereby reducing manufacturing cost.
Solution Approach 2:
The material properties of the contact carrier are modified by incorporating elastomeric material or elastomeric coating, enabling the lamella to exhibit flexible, resilient behavior without requiring additional metal spring parts or complex material treatments.
3Reliability
If additional parts are used for vibration protection, then vibration protection is improved, but compactness is reduced
Solution Approach 1:
The flexible lamella is formed as an integral part of the contact carrier body, utilizing the existing structural space rather than adding external components. This maintains the compact design of the plug connection while providing effective vibration protection.
4Stability of the object's composition
If high rigidity elements are used for vibration protection, then structural stability is improved, but haptics and reproducibility deteriorate
Solution Approach 1:
The contact carrier material is changed to include elastomeric properties or elastomeric coating, enabling the lamella to exhibit flexible, resilient behavior with well-defined spring characteristics. This provides reproducible haptic feedback during manual operation while maintaining structural stability through the wave-like moment curve.
5Stability of the object's composition
If high rigidity elements are used for vibration protection, then structural stability is improved, but wear increases
Solution Approach 1:
The use of elastomeric material or coating on the flexible lamella provides inherent damping and shock absorption properties, reducing impact loads and wear on the screw-threaded part interface. The resilient material conforms to the toothing profile, distributing contact stresses and minimizing wear while maintaining structural stability.
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 provides effective vibration protection with improved haptics and reproducibility, reduced wear, and maintained spring properties over time, while maintaining a compact form factor and avoiding the drawbacks of additional parts and high rigidity elements.
Implementation Method 1
at least one on its in the figure 2 and 4 marked connection "x - x" almost firmly clamped and at its free end approximately radially deflectable flexible lamella 1.1/3.1
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The plug or socket has a contact holder (1) with contact chambers for receiving contact partners. The holder has axial stop surfaces (1.5, 1.6) for receiving threaded parts and a bearing surface serving as a pivot bearing. The holder has a bending plate (1.1) in an area of the bearing surface, where the bending plate is radially movable. The plate is provided with edge surfaces that point in moveable direction and are normally adjusted.