Mechanical Interlock Base Plate and Adapter System
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Solution Overview
Problem
The assembly and manufacturability of mechanical interlocks are challenging due to their complexity and tight space constraints, and they often lack protection against environmental and physical damage.
Innovation Solution
Incorporating a base plate for easier assembly and an adapter system that allows different sized connectors to couple to a common contact carrier bracket, along with keying features to ensure proper positioning, and integrating printed circuit boards for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a base plate is incorporated for easier assembly, then ease of manufacture is improved, but device complexity increases
Solution Approach 1:
The mechanical interlock is divided into modular components including a base plate, contact carrier bracket, adapter, and enclosure. The base plate serves as a separate assembly platform that simplifies the assembly process by providing a structured foundation for mounting components, while the modular architecture allows each segment to be manufactured and assembled independently, reducing overall manufacturing difficulty despite increased component count.
2Adaptability or versatility
If an adapter system is used to allow different sized connectors to couple to a common contact carrier bracket, then adaptability is improved, but device complexity increases
Solution Approach 1:
A universal contact carrier bracket is designed with standardized mounting features and interface geometry that can accommodate multiple connector sizes and types through the use of interchangeable adapters. The adapter system provides multi-functionality by enabling the same base bracket to interface with various plug configurations (different pin arrangements, sizes, and orientations), thereby achieving versatility without requiring multiple specialized brackets for each connector type.
3Reliability
If keying features are implemented to ensure proper positioning, then reliability is improved, but ease of manufacture worsens
Solution Approach 1:
Keying features including asymmetric keys, keyways, and positioning protrusions are incorporated into the adapter and bracket interfaces to ensure correct orientation and positioning of components during assembly. These asymmetric geometric features prevent incorrect installation by allowing only the proper rotational and positional alignment, thereby guaranteeing reliable electrical and mechanical connections while maintaining relatively simple manufacturing processes through conventional machining or molding of the keying elements.
4Reliability
If protection against environmental and physical damage is provided, then reliability is improved, but device complexity increases
Solution Approach 1:
Protective features such as recesses, shielding structures, and robust mounting arrangements are built into the design of the contact carrier bracket and adapter assembly to preemptively protect vulnerable components (electrical contacts, connectors, and internal mechanisms) from environmental factors (dust, moisture, corrosion) and physical damage (impact, vibration, misuse). These protective elements are integrated into the existing structural components rather than added as separate complex subsystems, providing protection while minimizing increases in overall device complexity.
Data Source
AI summary
A mechanical interlock including one or more features to facilitate easier assembly and/or manufacturing. Additionally, and/or alternatively, the mechanical interlock may include one ore more features to provided increased protection. The mechanical interlock may include a baseplate arranged and configured to receive one or more components thereon so that the components can be coupled and wired as a sub-assembly prior to inserting into the enclosure. The mechanical interlock may include an adapter positioned between a connector and a contact carrier bracket to enable variously sized connectors to be coupled to a common contract carrier bracket. The adapter may include one ore more keys to prevent improper coupling of the adapter. The contact carrier bracket may be arranged and configured to receive one or more PCBs to provide an increased level of protection for the PCB.