Floating High-Voltage Connector Assembly for Mating Misalignment
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Solution Overview
Problem
Existing low-voltage signal connectors in high-voltage power connectors are fixed and cannot absorb mounting and manufacturing errors, making the mating operation difficult.
Innovation Solution
A floating mechanism with a first spring and multiple second springs allows the insulating housing to float in three perpendicular directions, enabling the connector to accommodate mounting and manufacturing errors, ensuring easy mating with the mating connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the low-voltage signal connector is fixed in the high-voltage power connector, then the structure is simple and stable, but the connector cannot absorb mounting and manufacturing errors, making mating operation difficult
Solution Approach 1:
The patent introduces a floating mechanism that allows the insulating housing to move dynamically in three directions (axial, radial, and circumferential) relative to the mounting portion. This dynamic capability enables the connector to absorb mounting and manufacturing errors, significantly improving ease of mating operation while maintaining structural simplicity through the use of spring elements.
Solution Approach 2:
The patent changes the positional parameters of the insulating housing by introducing floating capability in three directions. The first spring enables axial floating, while multiple second springs enable radial and circumferential floating. This parameter change allows the connector to adapt to positioning variations, resolving the contradiction between operational ease and structural complexity.
2Reliability
If the insulating housing is fixed to the mounting portion, then the connector structure is stable, but mounting and manufacturing errors cannot be absorbed
Solution Approach 1:
The patent implements beforehand cushioning by pre-installing a floating mechanism with spring elements between the insulating housing and mounting portion. This cushioning structure anticipates and absorbs mounting and manufacturing errors before mating operation occurs, ensuring reliable power control while compensating for positioning inaccuracies.
Solution Approach 2:
The floating mechanism transforms the rigid fixed connection into a dynamic connection that can adapt to positioning variations. The first spring provides axial floating capability, and the multiple second springs provide radial and circumferential floating capability, allowing the system to maintain reliability despite manufacturing tolerances.
3Adaptability or versatility
If a floating mechanism with springs is introduced, then mounting and manufacturing errors can be absorbed, but the device complexity increases
Solution Approach 1:
The floating mechanism is segmented into distinct functional components: a first spring for axial floating and multiple second springs for radial and circumferential floating. This segmentation allows each spring to handle specific directional movements, improving adaptability while keeping the overall structure manageable through clear functional division.
Solution Approach 2:
The floating mechanism serves multiple functions simultaneously: it absorbs mounting errors, compensates for manufacturing tolerances, enables easy mating operation, and maintains reliable power control. This multi-functionality justifies the added complexity by delivering comprehensive performance benefits across multiple operational requirements.
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 floating mechanism effectively absorbs mounting and manufacturing errors, facilitating easy mating operations and reliable power-on/power-off control of the high-voltage power terminal.
Implementation Method 1
The first spring is compressed in an axial direction of the insulating housing between the insulating housing and the mounting portion. The first spring enables the insulating housing to float in the axial direction.
Implementation Method 2
The plurality of second springs are spaced apart in a circumferential direction of the insulating housing and stretched in a radial direction of the insulating housing between the insulating housing and the mounting portion. The plurality of second springs enable the insulating housing to float in the radial direction.
Data Source
AI summary
A connector includes an insulating housing, a terminal disposed in the insulating housing, a mounting portion mounted to a fixing member, and a floating mechanism disposed between the insulating housing and the mounting portion. The floating mechanism enables the insulating housing to float in three directions perpendicular to each other relative to the mounting portion. The floating mechanism has a first spring and plurality of second springs. The first spring is compressed in an axial direction of the insulating housing between the insulating housing and the mounting portion. The first spring enables the insulating housing to float in the axial direction. The plurality of second springs are spaced apart in a circumferential direction of the insulating housing and stretched in a radial direction of the insulating housing between the insulating housing and the mounting portion. The plurality of second springs enable the insulating housing to float in the radial direction.