High-Voltage Plug Contact Element Assembly Simplification
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Solution Overview
Problem
The assembly of high-voltage plug-and-socket connectors is complex and prone to errors due to the need for precise connection of individual parts, requiring extensive training and documentation, which can lead to unreliable connections and increased risk of faults in harsh environments like vehicles.
Innovation Solution
A plug element design featuring a conductor fastening section with a pin receptacle and a conductor latching element, allowing for preassembly and simplified assembly by automatically latching the electrical conductor, reducing the number of components and assembly steps, and enabling easy disconnection for repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual parts are assembled manually with complex procedures, then connection precision can be achieved, but assembly complexity and error risk increase significantly
Solution Approach 1:
The conductor fastening section and contact element are merged into a single integrated component. The conductor fastening section is formed as one piece with the contact element, eliminating the need for separate assembly steps and reducing the number of parts that need to be manually connected.
Solution Approach 2:
The conductor is pre-fastened to the contact element in a preliminary assembly step before final insertion into the housing. This preliminary action ensures proper positioning and connection integrity before the component is installed in the final assembly, reducing errors during final assembly.
2Manufacturing precision
If extensive training and documentation are provided for assembly, then assembly precision improves, but assembly time and productivity decrease
Solution Approach 1:
The integrated design with automatic conductor fastening allows the assembly process to be self-guiding. The geometry of the conductor fastening section and conductor entry opening automatically guide the conductor into the correct position and secure it without requiring trained operators or complex documentation.
Solution Approach 2:
By combining the conductor fastening function and contact element into one integrated component, the assembly process is simplified to a single insertion operation, dramatically improving productivity while maintaining precision.
3Reliability
If multiple separate components are used for conductor connection, then connection reliability can be maintained, but assembly steps and potential error sources increase
Solution Approach 1:
The conductor fastening section and contact element are combined into a single integrated component that performs both functions simultaneously. This eliminates multiple assembly steps while maintaining connection reliability through the integrated design that ensures proper conductor securing and electrical contact.
Solution Approach 2:
The conductor is pre-fastened in the conductor fastening section before final assembly. This preliminary action ensures the conductor is securely positioned and connected before the component is inserted into the housing, reducing assembly time while maintaining reliability.
Data Source
Figure 1
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AI summary
The invention relates to a plug element (2) for a sealed high-voltage plug-and-socket connector (1), by means of which, in particular in an automobile, an electrical conductor (11) can be connected in electrically conductive manner to a mating contact element (46) of a mating plug element (3), with a housing body (7) which has a plug section (4) which can be fitted together with the mating plug element (3) in a direction of insertion (S) and a conductor receptacle section (6) remote from the plug section (4) with at least one conductor entry opening (10), and with at least one contact element (33) which has an insertion member (35) which is arranged spaced apart from the at least one conductor entry opening (10) in the plug section (4) and can be fitted together with the mating contact element (46), and a conductor fastening section (36) for connecting the at least one electrical conductor (11). Furthermore, the invention relates to a conductor end piece (26) for fastening an end section (55) of the electrical conductor (11) in the plug-and-socket connector (1) and also a modular system for the plug element (2), and to a method for assembling the plug element (2). In order to make the assembly of the plug element (2) simpler and more reliable, provision is made according to the invention for the conductor fastening section (36) to be designed as a plug contact (37) which is flush with the at least one conductor entry opening (10) in a direction of introduction (E) for the at least one electrical conductor (11) and for a conductor latching element (57, 57') to be arranged in the housing body (7), which element in a projection in the direction of introduction (E) overlaps the at least one conductor entry opening (10) at least in sections.