Modular Connector Housing With Selectable Insert Elements
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Solution Overview
Problem
Conventional plug connectors exhibit a high variance in housing designs and cable outlet configurations, leading to complexities in manufacturing, production control, and logistics, as different housings are required to accommodate various cable sizes and orientations, resulting in logistical challenges and increased costs.
Innovation Solution
A modular system where insert elements with different functionalities are used to reduce housing variants, allowing for the same external design housings to be produced with selected insert elements providing specific functionalities, which are either encapsulated during housing production or attached post-manufacturing, forming a cohesive and secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different housing designs are used to accommodate various cable sizes and orientations, then the adaptability of the connector is improved, but the device complexity and logistics complexity increase
Solution Approach 1:
The connector is divided into a standardized housing and separate insert elements. The housing provides a uniform base structure, while insert elements provide the variable functionalities for different cable sizes and orientations. This segmentation allows the housing to remain simple while achieving high adaptability through modular insert elements.
Solution Approach 2:
A single universal housing design is created that can accommodate multiple types of insert elements. The housing includes standardized features such as insert openings and cable outlets that work with various insert elements, allowing one housing type to serve multiple functions and reduce the need for multiple housing variants.
2Adaptability or versatility
If multiple housing variants are produced to meet different functional requirements, then the adaptability is improved, but the manufacturing complexity and production control difficulty increase
Solution Approach 1:
Manufacturing is segmented into producing a standardized housing and producing various insert elements separately. This allows the housing to be manufactured once in large quantities using optimized processes, while insert elements can be produced in smaller batches to match specific functional requirements, reducing overall manufacturing complexity.
Solution Approach 2:
The housing is produced in advance with standardized features prepared for receiving insert elements. Insert openings, cable outlets, and other mounting features are pre-configured in the housing design, allowing insert elements to be easily attached later without requiring complex reconfiguration of the housing manufacturing process.
3Adaptability or versatility
If all housing variants are kept available in the supply chain to meet different needs, then the adaptability is improved, but the logistics complexity and supply chain challenges increase
Solution Approach 1:
A single universal housing design is distributed throughout the supply chain instead of multiple housing variants. This universal housing can be combined with different insert elements at the point of use, dramatically reducing the number of unique parts that need to be managed in the supply chain while maintaining the ability to meet diverse customer requirements.
Solution Approach 2:
The product is segmented into a standardized housing and interchangeable insert elements. Only the housing and a limited set of insert elements need to be maintained in the supply chain, rather than numerous complete connector variants. This segmentation reduces inventory requirements and simplifies supply chain management.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
In a method for manufacturing a connector (1) for plugging in with an associated mating connector (2), a housing (10) is manufactured in which a contact insert (13) is to be received, which forms a plug-in face (11) for plugging in with the mating connector (2) and has at least one electrical contact element (130) for electrical contact with at least one mating contact element (200) of the mating connector (2).The method also provides that a plurality of insert elements (12) intended for use on the connector (1) and designed to provide different functionalities on the connector (1) are provided, at least one insert element (12) is selected from the plurality of insert elements (12), and at least one selected insert element (10) is connected to the housing (10) during the manufacture of the housing (10) or joined to the housing (10) after the manufacture of the housing (10).