Lever-Cam Connector Assembly for Vibration-Resistant Contact Pressure
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Solution Overview
Problem
Existing connector assemblies face challenges in maintaining contact reliability between connectors due to external forces like vibration, which can cause contact failure, and increasing the contact force to improve reliability makes the fitting operation more difficult and may damage the contact surfaces.
Innovation Solution
A connector assembly that includes a first and second connector, a lever member, a rotational shaft member with a cam surface, and a cam mechanism. The lever member rotates to move the second insulator to a fitting position, and the cam surface presses the contacts together with a predetermined contact pressure, ensuring reliable connection without excessive force or surface damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact force between the first contact and the second contact is increased to improve contact reliability, then the contact reliability improves, but the insertion force required for fitting the connectors increases and the contact surfaces may be damaged
Solution Approach 1:
The lever member transitions from an initial position to a fitted position through rotation, dynamically changing the contact force between contacts. During the fitting operation, the lever member's rotation automatically adjusts the contact force to an appropriate level, avoiding both insufficient contact reliability and excessive insertion force that could damage contact surfaces
Solution Approach 2:
The contact force parameter is changed through the rotation of the lever member. As the lever member rotates from the initial position to the fitted position, the contact force between the first and second contacts is adjusted to an optimal value, resolving the contradiction between needing high contact reliability and avoiding excessive insertion force
2Reliability
If the contact force between the first contact and the second contact is increased to improve contact reliability, then the contact reliability improves, but the contact surfaces may be damaged
Solution Approach 1:
The lever member's rotation dynamically adjusts the contact force to maintain it within a safe range that ensures reliability without damaging contact surfaces. The mechanical structure automatically limits the maximum contact force during the fitting operation
Solution Approach 2:
The contact force parameter is precisely controlled through the lever member's rotation mechanism, changing from zero to an optimal value that ensures contact reliability while preventing surface damage
3Power
If a thicker electric wire is used to handle higher electric current, then the current carrying capacity improves, but the external force transmission to the contacting part increases causing contact failure
Solution Approach 1:
The contact force parameter is optimized to maintain reliable electrical connection while minimizing the transmission of external forces from thick electric wires. The lever member's rotation mechanism ensures the contact force remains within an appropriate range even when high current flows through thick wires
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables easy fitting of connectors while maintaining high contact pressure, ensuring reliable electrical connection even under external forces like vibration, and preventing surface damage to the contacts.
Implementation Method 1
a rotational shaft member extending along the rotational axis and rotating in accordance with rotation of the lever member, the rotational shaft member including a cam surface for pressing the first contact and the second contact against each other
Implementation Method 2
a lever member held by one of the first insulator and the second insulator in a rotatable manner about a rotational axis
Implementation Method 3
a cam mechanism moving the first insulator and the second insulator relatively along the fitting direction in conjunction with rotation of the lever member
Data Source
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AI summary
A connector assembly includes a first connector having a first insulator and a first contact, a second connector having a second insulator and a second contact and being fitted to the first connector along a fitting direction; a lever member held by one of the first insulator and the second insulator in a rotatable manner about a rotational axis, a rotational shaft member extending along the rotational axis and rotating in accordance with rotation of the lever member, the rotational shaft member having a cam surface for pressing the first contact and the second contact against each other, and a cam mechanism moving the first insulator and the second insulator relatively along the fitting direction in conjunction with rotation of the lever member.