Interlocking Coding Elements for Plug Connector Alignment
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Solution Overview
Problem
Existing coding devices for connectors are often designed as auxiliary solutions and fail to provide a simple, unmistakable, and encodable plug connection for hybrid connectors with both power and signal contacts, leading to potential misconnections.
Innovation Solution
The solution involves a coding device with flat coding elements that have interlocking structures with vertical, horizontal, sloping, and curved parts, which are inserted into a slot opening in the connector body, ensuring a precise fit and correct alignment, and are protected by a metallic shielding sleeve for secure and correct plugging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coding elements are added to prevent misconnections, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The coding elements are integrated directly into the connector body structure, merging the coding function with the mechanical connector components. This eliminates separate auxiliary coding devices and reduces overall complexity while maintaining reliable coding functionality.
Solution Approach 2:
The coding elements serve multiple functions: they provide unique identification codes, guide the plugging direction, and prevent misconnections. This multi-functionality reduces the need for separate components and simplifies the overall connector design.
2Reliability
If multiple coding structures are used to ensure unmistakable plugging, then connection reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The coding elements are designed as separate, modular components that can be independently manufactured and then assembled into the connector body. This segmentation allows for simplified manufacturing of individual parts while achieving complex coding functionality through combination.
Solution Approach 2:
The coding structures utilize variations in geometric parameters (shapes, sizes, positions) of simple features rather than complex structures. This allows multiple coding configurations to be achieved through parameter variations of basic geometric forms, simplifying manufacturing.
3Reliability
If coding elements with precise fit are used, then connection reliability is improved, but ease of operation decreases
Solution Approach 1:
The coding elements feature asymmetric geometries that provide precise fit and prevent misconnections, while the overall connector design incorporates guiding features that align the asymmetric coding elements automatically during insertion. This resolves the conflict between precise fitting and ease of operation.
Solution Approach 2:
The connector design includes preliminary guiding features and alignment mechanisms that prepare the coding elements for engagement before the actual plugging action. This preliminary alignment reduces the operational effort required while maintaining precise fit during connection.
Data Source
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AI summary
For unambiguous mating of two connectors (1, 2), a mating-side coding is provided, which can be inserted within a slot opening (12) in the connector body (10) in the form of area-like coding elements (20). It is provided that a coding element (20, 20') is inserted in each of the connectors (1, 2), which has mutually interlocking structures (22, 22') for a codable mating.