Internal Locking Mechanism for High-Current Connectors Under Load
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Solution Overview
Problem
Existing electrical connector solutions for high-current applications are bulky, prone to contamination and damage, and lack robust locking mechanisms that prevent 'pulling under load, posing safety risks.
Innovation Solution
A compact, internal locking device with an electromechanical mechanism and electronic components ensures secure locking of electrical connectors, preventing disconnection during operation, and includes an RFID system for safe voltage detection and visual indicators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pivotable locking clip with monitoring electronics is used to prevent pulling under load, then the electrical connection safety is improved, but the device size becomes very large
Solution Approach 1:
The locking mechanism is extracted from the external monitoring system and integrated directly into the plug itself. The plug contains its own locking elements (lugs with spring fingers) that engage with the socket, eliminating the need for large external locking clips and monitoring electronics while maintaining safety functionality.
Solution Approach 2:
The locking mechanism is nested within the plug structure. The spring fingers are integrated into the plug body, and the locking lugs are formed as part of the plug's internal structure. This nesting allows the locking function to be contained within the existing plug volume without requiring additional external components.
2Device complexity
If the locking mechanism is attached to the outside of the locking clip, then the locking function is simplified, but the mechanism becomes prone to contamination and damage
Solution Approach 1:
The locking lugs and spring fingers are nested within the plug and socket bodies respectively. The spring fingers are housed within recesses in the plug, and the locking surfaces are internal to the connection interface. This nesting protects the locking mechanism from external contamination and physical damage while maintaining the simplicity of the spring-based locking action.
3Reliability
If a mechanical locking system is used to prevent pulling under load, then the connection reliability is improved, but the system becomes more complex
Solution Approach 1:
The spring fingers automatically engage with the locking lugs when the plug is inserted into the socket, and automatically disengage when the plug is pulled out. The spring mechanism provides self-actuating locking and unlocking functionality without requiring external control systems, motors, or complex actuation mechanisms, thereby maintaining simplicity while ensuring reliable mechanical locking.
Data Source
AI summary
An electrical connector socket is provided, which has a locking device with which an electrical connector can be locked to the electrical connector socket when plugged in, wherein the locking device is arranged at least partly inside the electrical connector socket and protrudes at least partly from the electrical connector socket on the plug-in side. The electrical connector is provided for transmitting high currents and signals, wherein the electrical connector as a locking contour, into which a locking device of an electrical connector socket can engage, wherein the locking contour is arranged on the electrical connector on the plug-in side.