Lever-Locked Plug Connection for Automated High-Force Coupling
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Solution Overview
Problem
Existing plug connections require manual and sequential steps for assembling the coupling housing onto a pin strip housing, which is time-consuming and prone to human error, and may cause damage under higher plugging forces.
Innovation Solution
A plug connection design featuring a rotatable lever with a projection that generates a counter force, allowing the coupling housing to be automatically locked into place by rotating the lever from a pre-locking to a final locking position using the applied plugging force, eliminating the need for manual manipulation and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual guidance is used to position the coupling housing onto the pin strip housing, then the assembly can be completed, but the process is time-consuming and prone to human error
Solution Approach 1:
The lever is designed to automatically perform the positioning function during the plugging process. When plugging force is applied, the lever self-activates and rotates from the pre-locking position to the final locking position without requiring manual intervention, thereby eliminating manual manipulation while maintaining ease of operation
Solution Approach 2:
The lever is pre-positioned in a pre-locking position where the coupling housing is preliminarily arranged on the pin strip housing. This preliminary positioning enables the automated transition to the final locking position when plugging force is applied, facilitating quick automated assembly
2Reliability
If higher plugging forces are applied to ensure secure connection, then the mechanical connection becomes more reliable, but the risk of damage to components increases
Solution Approach 1:
The lever acts as an intermediary mechanical element that mediates between the applied plugging force and the locking mechanism. It distributes and controls the force transmission, enabling secure locking while reducing peak stresses on individual components, thus maintaining reliability while minimizing damage risk
Solution Approach 2:
The lever transitions dynamically from a pre-locking position to a final locking position during the plugging process. This dynamic movement allows the system to adapt the locking force progressively, ensuring reliable connection while avoiding sudden high-force impacts that could cause component damage
Data Source
Figure 1~2A
Figure 2B~3
AI summary
A plug connection for electrically and mechanically coupling at least two electrical conductors is disclosed, having a coupling with at least one bushing element which is arranged in a coupling housing and which is for receiving at least one pin contact in a form-fitting manner and with a lever with at least one locking element, the lever being rotatably mounted at the coupling housing in an orthogonal manner relative to a plug-in direction, having a pin strip with at least one pin contact arranged in a pin strip housing and with at least one recess introduced into the pin strip housing for receiving the at least one locking element, wherein, in a pre-locking position, the coupling housing is arranged at least in sections on the pin strip housing in a form-fitting manner and the at least one locking element is arranged adjacent to the at least one recess and by rotating the lever the at least one locking element can be brought into an operative connection with the at least one recess, wherein at least one projection is arranged between the lever and the pin strip housing and, when a plugging force is applied onto the coupling housing, a counter force which is directed against the plugging force can be generated on the lever by the projection.