Linear Locking Electrical Connectors with Ring and Arm Mechanism
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Solution Overview
Problem
Electrical connectors in vehicles or movable objects are prone to failure due to movements and vibrations, leading to broken connections and damage beyond normal wear and tear.
Innovation Solution
A linear locking mechanism is introduced, comprising a ring and arm locking device that secures male and female bullet connectors together, with a wiper ring and bumps/recesses for a firmer grip, and a second bumper to prevent backward movement, ensuring the connectors remain connected even under extreme conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is added to prevent connector separation under vibration, then reliability is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is nested within the connector structure itself. The locking arm is integrated into the housing, and the locking hook is formed as part of the plug connector assembly. This nesting approach allows the locking function to be incorporated without significantly increasing overall device complexity, as the locking components are embedded within the existing connector geometry rather than being separate external additions.
Solution Approach 2:
The locking mechanism operates through self-service principles where the locking arm automatically engages with the locking hook when the plug is inserted into the receptacle. The spring-loaded arm provides automatic locking action without requiring external actuation or complex control systems. The design allows the connector to lock itself through the natural insertion motion, improving reliability while minimizing added complexity.
2Strength
If a locking mechanism with multiple components is used to prevent connector failure, then strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
The locking arm and spring are combined as an integrated assembly that moves together as a single unit during insertion and locking. The locking hook is formed as an integral part of the plug connector housing rather than being a separate component. This merging of components reduces the number of discrete parts that need to be manufactured and assembled, thereby improving ease of manufacture while still providing the necessary coupling strength through the unified locking structure.
3Reliability
If bumpers are added to prevent backward movement of the locking ring, then reliability is improved, but device complexity increases
Solution Approach 1:
The bumper is implemented as a localized feature within the existing connector structure rather than a separate major component. The first bumper is integrated into the housing near the locking mechanism, and the second bumper is positioned at the rear of the plug connector. These localized bumper features provide position stability and prevent backward movement of the locking ring with minimal impact on overall device complexity, as they are incorporated into the existing connector geometry rather than being additional standalone components.
Data Source
AI summary
An electrical connector apparatus, including: a first connector coupled to a first end of an electrical wire, the first connector including a locking hook; a second connector coupled to a second end of the electrical wire, the second connector including a first bumper; and a locking device configured to keep the first connector and the second connector coupled together and to keep the first end and the second end of the wire connected, the locking device including a ring and an arm, wherein the ring is configured to insert over the second connector until the ring is flush with the first bumper of the second connector, and the arm hooks onto the locking hook of the first connector when the ring is flush with the first bumper of the second connector.