Lever-Preloaded Plug Connection to Eliminate Latch Play
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Solution Overview
Problem
Existing plug connections experience latch play and increased transition resistance due to relative movement between the main and mating connectors, leading to potential contact abrasion under vibration loads.
Innovation Solution
A sleeve surrounds the main connector, and a lever mechanism connects the main and mating connectors, enhanced by a spring to increase prestressing force, preventing latch play and contact abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional direct latching connection is used between main connector and mating connector, then the structure is simple, but latch play occurs and transition resistance increases
Solution Approach 1:
The latching structure is segmented into a lever mechanism with distinct components: a lever arm, pivot point, latching protrusion, and corresponding recess. This segmentation allows independent optimization of each component's function, enabling the lever to amplify force while the protrusion-recess interface provides precise positioning and eliminates latch play.
Solution Approach 2:
The lever acts as an intermediary mechanical element between the main connector and mating connector. It mediates the force transmission by converting small displacement at one end into amplified force and displacement at the other end, thereby achieving both simple operation and reliable latching without direct rigid connection.
2Reliability
If high prestressing force is applied to eliminate latch play, then connection stability improves, but contact abrasion occurs in vibration-loaded inserts
Solution Approach 1:
The latching system transitions from a static rigid connection to a dynamic lever-based connection that can adapt to vibration loads. The lever mechanism allows for elastic deformation and energy absorption during vibration cycles, reducing the transmission of harmful forces to the contact surfaces while maintaining continuous contact pressure to eliminate latch play.
Solution Approach 2:
The lever mechanism is designed with inherent compliance that cushions against vibration-induced shocks before they can cause contact abrasion. The lever arm acts as a mechanical cushion, absorbing and dissipating vibration energy through controlled deformation, thereby protecting the contact surfaces from harmful abrasive forces.
3Ease of operation
If manual assembly is used for plug connections, then ease of operation is maintained, but achieving high prestressing force is difficult
Solution Approach 1:
The system replaces direct mechanical force application with a lever-based mechanical advantage system. Instead of relying on manual assembly force alone, the lever mechanism amplifies the applied force through its geometric configuration, enabling high prestressing forces to be achieved with minimal manual effort while maintaining ease of operation.
Solution Approach 2:
The lever mechanism changes the force parameter by amplifying the input force through its mechanical advantage ratio. By adjusting the lever arm lengths, the system can optimize the force multiplication effect, transforming small manual assembly forces into high prestressing forces capable of eliminating latch play without requiring complex assembly equipment.
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 effectively reduces latch play and maintains stable transition resistance, ensuring secure and durable connections even under vibration loads by increasing the prestressing force through the lever mechanism and spring assistance.
Implementation Method 1
a spring, preferably a leaf spring, is provided on the edge of the slot facing the pin housing that spring biases the pin housing toward the main connector and at the same time clamps the plug connection
Implementation Method 2
the main connector, mating connector or pin housing and the sleeve are operatively connected to one another by a lever mechanism and can be braced against one another. As a result of this configuration, the plug connection can be pre-tensioned substantially more forcefully than is normally possible by the applied assembly force. The lever mechanism increases the prestressing force
Data Source
AI summary
Plug-in connection, comprising a plug-in connector (1) which can be plugged together with a mating plug-in connector, also known as a pin housing (2), it being possible to at least indirectly lock the plug-in connector (1) with the mating plug-in connector (2), characterised in that a bushing housing (3) is provided which at least partially surrounds the plug-in connector (1) and provides the locking with the mating plug-in connector or pin housing (2), and in that the plug-in connector (1), the mating plug-in connector or the pin housing (2) and the bushing housing (3) are operatively interconnected by means of a lever mechanism and can be braced together.