Helical Groove Power Socket for Stable High-Current Connection
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Solution Overview
Problem
Existing electrical sockets for high-current applications, such as welding systems, suffer from low release torque, leading to unintentional disconnection due to temperature fluctuations or vibrations, resulting in increased contact resistance and potential overheating, which can damage components and disrupt processes.
Innovation Solution
The socket design features a helical groove with alternating positive and negative pitches, a spring-loaded sleeve, and a harder material for the sleeve, allowing for increased release torque and haptic feedback, while maintaining a secure connection and enabling gas passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a helical groove with steep pitch is used in the socket, then the connection length is reduced, but the release torque becomes too low causing unintentional disconnection
Solution Approach 1:
The helical groove is segmented into multiple sections with alternating positive and negative pitches. The positive pitch sections provide locking action while the negative pitch sections provide release action, creating distinct functional zones within the groove that enable reliable connection and controlled disconnection
Solution Approach 2:
The helical groove features periodic alternation between positive and negative pitch sections, creating a repeating pattern of locking and release zones. This periodic structure allows the connection to be securely locked during operation while enabling intentional release when needed
2Ease of operation
If the helical groove has low release torque, then the connection is easy to disconnect, but unintentional disconnection occurs due to temperature fluctuations or vibrations
Solution Approach 1:
The connection system transitions from a static friction-based hold to a dynamic mechanical locking system. The positive pitch sections create active locking zones that actively resist disconnection forces, while the negative pitch sections provide controlled release paths, making the connection stable under vibration and temperature changes
3Reliability
If the connection is secured with high preload force, then connection stability is improved, but the energy required to disconnect increases
Solution Approach 1:
The disconnection process is segmented into multiple stages corresponding to the negative pitch sections of the helical groove. Instead of requiring one large energy input to overcome all preload forces at once, the connection releases progressively through defined release zones, reducing the peak energy requirement
Solution Approach 2:
The negative pitch sections act as intermediaries that facilitate controlled release. These sections provide a mechanical pathway that guides the locking lug through a controlled disengagement process, converting the high preload force into a manageable release sequence
4Ease of manufacture
If the socket and plug are made of soft material for ease of manufacturing, then manufacturing is easier, but wear increases leading to increased contact resistance
Solution Approach 1:
The socket assembly uses composite construction with the receptacle made of softer material for ease of manufacturing and the sleeve made of harder material for wear resistance. This composite approach allows each component to be optimized for its specific function while maintaining manufacturing feasibility
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 a stable, low-resistance connection that minimizes the risk of unintentional disconnection, reduces overheating, and maintains process integrity by ensuring consistent contact and reduced wear on the socket.
Implementation Method 1
wenn in dem Aufnahmeraum für die Hülse ein Federelement zur federnden Unterstützung der Hülse in axialer Richtung des Aufnahmeraumes angeordnet ist
Implementation Method 2
wenn die Gewingegroove des Grundkörpers des Steckers mindestens zwei Bereiche mit positivem Gewindegang aufweist und am Ende jedes Bereichs mit positivem Gewindegang Bereiche mit negativem Gewindegang zur Bildung eines Detent-Schritts angeordnet sind
Data Source
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AI summary
: The invention relates to a power jack (1) for releasable connection to a power plug (30), with a main body (2) made of electrically conductive material with a bore (2') for receiving a substantially cylindrical pin (31) of the power plug (30) and with a device (4) for connection to a power cable (40), wherein a helical groove (5) for receiving a locking nose (32) of the power plug (30) is arranged in the main body (2), wherein the main body (2) of the power jack (1) has a sleeve (3) with the helical groove (5) and a receptacle (3') for the sleeve (3). The invention also relates to a power coupling (50) having such a power jack (1) and an associated power plug (30). According to the invention, the helical groove (5) has at least two regions (a, c) with positive slope, and at the end of each region (a, c) with positive slope regions (b, d) with negative slope are arranged to form in each case a latching stage, and the receptacle (3') is made of metal or a metal alloy with a sheath (13) of electrically insulating material and the sleeve (3) is formed from harder material than the receptacle (3').