Floating Pin Electrical Connector for High Power Motor Controllers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High power motor controllers with blind mating connectors face alignment issues due to tolerances, leading to insecure connections and accelerated wear from micro movements, especially under vibration, at high current levels.
Innovation Solution
A floating electrical connector design featuring a pin that can move axially and radially within a socket with a conical interface, spring-biased to ensure consistent contact, allowing for alignment adjustment and secure connection even during misalignment and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a floating connector is used to allow alignment adjustment due to tolerances, then the ease of assembly is improved, but the connection security deteriorates due to lack of mechanical tie
Solution Approach 1:
The pin is designed to float within the socket bore, allowing dynamic adjustment of its position along the axis and radially. This dynamic capability enables the pin to self-align with the socket despite manufacturing tolerances, while the spring bias maintains secure contact. The floating mechanism transforms a static rigid connection into a dynamic adaptive connection that accommodates misalignment while maintaining security.
2Device complexity
If blind mating is used for large rack connections, then the device complexity is reduced, but the manufacturing precision deteriorates due to inability to ensure identical connector positioning
Solution Approach 1:
The invention changes the positional parameters of the pin by allowing it to float and move within the socket bore. Instead of requiring precise fixed positioning, the pin can adjust its position along the axis and radially to accommodate manufacturing variations. The spring bias parameter ensures the pin maintains contact while allowing this positional adjustment, effectively compensating for positioning precision issues.
3Reliability
If a fixed rigid connection is used, then the connection security is improved, but the adaptability deteriorates due to inability to accommodate tolerance variations
Solution Approach 1:
The pin is designed with floating capability that allows it to move dynamically within the socket bore to adapt to alignment variations. The spring bias provides continuous contact force to maintain security. This dynamic design combines the adaptability of a floating connection with the security of a biased contact, resolving the contradiction between rigidity and adaptability.
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 solution provides a secure and durable high-power electrical connection by allowing for radial and axial movement of the pin within the socket, ensuring consistent contact and reducing wear and vibration-induced issues.
Implementation Method 1
The pin is spring-biased into the bore such that an end of the pin seats on an end face of the bore
Data Source
AI summary
An electrical connection includes a socket having a bore and a pin. The pin is allowed to move along an axis defined inwardly into the socket bore, and also to move radially relative to the axis. The socket bore has a generally conical portion. The pin has a generally conical face. The generally conical face of the pin is in contact with the generally conical portion of the socket. A motor system including such a connection is also disclosed. In another feature, an electrical connection includes a socket having a bore and a pin. The pin is allowed to move along an axis defined inwardly into the bore, and also to move radially relative to the axis. The pin is spring-biased into the bore such that an end of the pin seats on an end face of the bore.