Modular Electrical Connector Frame for Retool-Free I/O Reconfiguration
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Solution Overview
Problem
Traditional electrical connector designs require retooling of the connector body to modify input/output terminal configurations, limiting flexibility and adaptability to different applications.
Innovation Solution
An electrical connector assembly featuring modular terminal modules and a frame with interchangeable module bays, allowing for customizable input/output configurations without the need for retooling, and incorporating locking mechanisms and a wire dress cover for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional molded connector bodies with fixed terminal cavities are used, then manufacturing simplicity is maintained, but adaptability to different applications deteriorates due to the inability to reconfigure terminal positions and types
Solution Approach 1:
The connector body is divided into multiple module bays that can independently receive different terminal modules. Each module bay is a discrete unit that can be independently configured, allowing the connector to be customized for different applications by selecting and arranging appropriate terminal modules in each bay.
Solution Approach 2:
The module bays are designed with universal interfaces that can accommodate multiple types of terminal modules. Each module bay can receive different terminal modules (e.g., electrical terminals, fiber optic terminals, coaxial terminals), enabling a single connector body to serve multiple functions and applications.
2Ease of operation
If terminal cavities are fixed in the molded connector body, then manufacturing precision is maintained, but ease of operation deteriorates due to the inability to reconfigure terminals without retooling
Solution Approach 1:
The connector design transitions from a static, fixed terminal configuration to a dynamic, reconfigurable system. Terminal modules can be removed and replaced in the module bays, allowing the connector to adapt its configuration over time without requiring retooling or permanent modification.
Solution Approach 2:
Multiple terminal modules are pre-manufactured with standardized interfaces that match the module bays. This preliminary preparation of interchangeable terminal modules enables rapid reconfiguration by simply plugging and unplugging modules, eliminating the time-consuming retooling process.
3Ease of manufacture
If hard changes to fabrication tools are required to modify terminal configuration, then manufacturing reliability is maintained, but ease of manufacture deteriorates due to the need for retooling
Solution Approach 1:
The terminal configuration is extracted from the molded connector body and placed into removable terminal modules. This separation allows the terminal arrangement to be modified by simply changing which modules are installed in the module bays, without requiring any changes to the connector body itself or the fabrication tools used to make it.
Data Source
AI summary
An electrical connector assembly includes a frame having a plurality of module bays and a plurality of terminal modules each having a housing and an electrical terminal disposed within a cavity in the housing. Each terminal module is configured to be received within any one of the plurality of module bays. The electrical connector assembly also includes a wire dress cover attached to the frame defining a plurality of posts contacting the plurality of terminal modules. A method of assembling an electrical connector is also provided.