Hybrid Connector System for Compact Drive Arrangement
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Solution Overview
Problem
Existing drive systems with electric motor drives, particularly servo drives, face challenges in efficiently connecting power and data between adjacent drives using hybrid cables, leading to space constraints and suboptimal arrangements due to the design of mating connectors and hybrid cables.
Innovation Solution
The drive system incorporates a hybrid connector system with a flat, arcuate hybrid cable and inclined mating connector plugs, allowing for a compact arrangement of drives along a circular or straight path, with busbars integrated into the mating connector housing for efficient power and data transmission, and a plastic overmold for sealing and strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional hybrid cables and mating connectors are used for connecting adjacent drives, then power and data transmission is achieved, but the drives require excessive space and cannot be positioned closely together
Solution Approach 1:
The connector plugs are designed with inclined plug-in surfaces that form an acute angle, transitioning from traditional orthogonal connections to angular connections. This dimensional change in connection geometry allows cables to be routed more efficiently and reduces the space required for connector clearance and cable bending radius, enabling tighter drive arrangements while maintaining connection reliability
Solution Approach 2:
The hybrid cable is designed as a flat, arcuate cable rather than a traditional round cable. This curved, flexible design allows the cable to bend at smaller radii and conform to tighter spaces between drives, reducing the minimum clearance required between adjacent drives while maintaining electrical connection integrity
2Productivity
If busbars are integrated into the mating connector housing, then power transmission efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The busbars are integrated directly into the mating connector housing, merging the power transmission function with the connector structure. This consolidation eliminates the need for separate busbar assemblies and reduces the number of assembly steps, actually simplifying manufacturing despite the enhanced power transmission capability. The injection molding process can incorporate busbars as integral features or pre-assembled components within the housing cavity
Solution Approach 2:
The mating connector housing serves multiple functions: it provides mechanical protection for connections, enables electrical power transmission through integrated busbars, and facilitates data transmission. This multi-functionality consolidates what would traditionally require separate components into a single integrated unit, improving power transmission efficiency while streamlining the overall assembly process
3Ease of operation
If the converter housing protrudes beyond the motor housing, then connector accessibility is improved, but the overall drive size increases
Solution Approach 1:
The converter housing is designed as an asymmetric half-shell structure that selectively protrudes only in the region where connector accessibility is required, rather than uniformly extending in all directions. This asymmetric design provides the necessary clearance for connector operations while minimizing the overall volume increase of the drive assembly
Data Source
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AI summary
The invention relates to a drive system with a number of electric motor drives (1), in particular servo drives, which or their electronics are connected or connectable to each other via a hybrid bridge (2) with a hybrid cable (33) and with a cable end connector (12) for current conduction and data transmission, as well as such a drive (1) and such a hybrid bridge (2).