Floating Connector Pivot Structure for Misalignment Stress Relief
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Solution Overview
Problem
Conventional connectors for coupling controllers to aerial lighting fixtures often face stress issues due to non-symmetrical devices with uneven weight distribution, leading to overstressing during installation, removal, and extreme weather conditions, as they do not have a symmetrical relationship with the luminaire or support arm.
Innovation Solution
A floating connector system with a substructure that allows for rotational motion and flexible sealing, integrated with the controller, enabling it to couple electromechanically with a standards-compliant female connector while accommodating misalignments and reducing stress through a range of motion, such as up to 5°, ensuring symmetrical coupling and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional connector is used to couple the controller to the aerial lighting fixture, then the electrical connection is established, but the connector is overstressed during installation, removal, and extreme weather conditions due to non-symmetrical device placement and uneven weight distribution
Solution Approach 1:
The connector is designed with a floating substructure that allows dynamic movement and rotation (up to 5 degrees) to accommodate misalignments and stress forces. This dynamic capability enables the connector to adapt to non-symmetrical device placements and uneven weight distribution without overstressing, thereby maintaining connection reliability while reducing mechanical stress on the connector body.
2Adaptability or versatility
If the controller is positioned non-symmetrically with respect to the luminaire or support arm, then installation flexibility is improved, but the connector experiences increased stress and potential failure
Solution Approach 1:
The floating substructure with rotational capability allows the connector to dynamically adjust to non-symmetrical positioning requirements. The connector can rotate up to 5 degrees to accommodate various installation configurations while maintaining proper electrical contact, thereby providing installation flexibility without subjecting the connector to excessive stress from misalignment.
Solution Approach 2:
The floating substructure acts as an intermediary element between the controller and the aerial lighting fixture. It absorbs and compensates for the stress caused by non-symmetrical positioning, allowing the main connector body to remain properly aligned and stress-free while enabling flexible device placement.
3Reliability
If a floating connector with rotational motion capability is implemented, then stress on the connector is reduced and installation flexibility is improved, but the device complexity increases
Solution Approach 1:
The floating substructure incorporates a simple rotational mechanism with a defined range of motion (up to 5 degrees) that provides the necessary stress relief and alignment compensation. This limited rotational capability achieves the reliability benefits without requiring complex multi-axis movement or sophisticated control systems, thereby balancing connection stability with manageable device complexity.
Data Source
AI summary
A floating connector includes a housing, a substantially planar surface positioned within the housing, a set of electrical contacts, and a bushing. The set of electrical contacts are arranged substantially normal to the planar surface. The bushing is cooperatively mated with the housing and the planar surface so as to permit the bushing to pivot the planar surface about one or more points. In one exemplary embodiment, the bushing defines a pair of diametrically opposite pin apertures. In such an embodiment, the floating connector may further include a pair of pivot pins, where each pivot pin passes through a respective one of the pin apertures and pivotally interconnects the bushing and the housing. Additionally, the housing may define a pair of diametrically opposite wells to receive the pivot pins. The floating connector may form part of an electronic apparatus that is mountable to a luminaire of a streetlight.