Floating Electrical Connector Alignment to Prevent Tilt Damage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing self-aligning electrical connectors for vehicles require complex and costly designs, particularly when connecting high-load and low-load contact elements, and are prone to damage due to tilting during assembly.
Innovation Solution
A self-aligning electrical connector system with a first connector part floatingly arranged on a support frame with three rotational and at least two translational degrees of freedom, using spring-loaded flat elements and a ball socket mechanism for alignment, allowing easy and safe attachment without damaging sensitive contact elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If connector parts are joined with complex alignment mechanisms, then alignment precision is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The alignment function is segmented into two independent parts: positioning pins on one connector part and positioning chambers on the mating connector part. This segmentation allows each component to be simple in design while collectively achieving precise alignment, avoiding the need for a complex integrated alignment mechanism.
Solution Approach 2:
Positioning pins act as intermediary elements that bridge the gap between the two connector parts during alignment. The pins engage with the positioning chambers to establish the correct relative position, serving as a simple yet effective mediator that eliminates the need for complex self-aligning mechanisms.
2Manufacturing precision
If connector parts are joined with complex alignment mechanisms, then alignment precision is improved, but manufacturing cost increases
Solution Approach 1:
By dividing the alignment function into separate positioning pins and positioning chambers, each component can be manufactured independently using standard machining processes. This segmentation reduces manufacturing complexity and cost compared to producing a single complex self-aligning mechanism.
Solution Approach 2:
The positioning pins and chambers are designed as simple, inexpensive features that can be easily manufactured and replaced if necessary. Their simplicity allows for cost-effective production while maintaining precise alignment functionality.
3Stability of the object's composition
If connector parts are rigidly fixed during assembly, then positioning stability is improved, but risk of damage to contact elements increases due to tilting
Solution Approach 1:
The connector part is designed with floating capability, allowing it to dynamically adjust its position and orientation during assembly. This dynamic adjustment enables the connector to compensate for misalignment and tilt, maintaining contact element integrity while achieving stable positioning through the positioning pins and chambers.
4Ease of operation
If floating arrangement with multiple degrees of freedom is used, then ease of alignment is improved, but device complexity increases
Solution Approach 1:
The floating arrangement is achieved through segmented support elements (positioning pins and chambers) rather than a complex continuous mechanism. Each support element provides specific degrees of freedom independently, simplifying the overall design while maintaining ease of alignment.
Solution Approach 2:
The floating connector part automatically aligns itself with the mating connector through the positioning pins and chambers without requiring external alignment tools or complex control mechanisms. The system serves itself by utilizing the geometric constraints provided by the positioning features.
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 simplifies the assembly process, prevents damage to contact elements, and enables cost-effective manufacturing, facilitating both manual and robotic attachment with improved alignment precision.
Implementation Method 1
a ball cup between the flat elements. The ball cup supports a ball that is in contact with the support frame
Implementation Method 2
The flat elements of the first connector part are loaded with a spring force by spring arms formed on the support frame
Data Source
AI summary
A self-aligning electrical connector system for data and/or energy transmission includes first and second connector parts and a support frame. The first connector part includes positioning pins, flat elements, and a ball socket positioned between the flat elements. The second connector part is attachable to the first connector part and includes positioning chambers engageable with the positioning pins to achieve a coarse positioning of the connector parts relative to one another. The support frame has a flat central bar including spring arms. A ball is supported by the ball socket. The first connector part is supported on the support frame by spring forces of the spring arms acting on the flat elements and is supported on the ball with the ball being rollable on the central bar whereby the first connector part is floatingly arranged on the support frame and is shiftable and tiltable relative to the support frame.