Modular Connector Locking and Sealing for Compact Rail Power Links
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Solution Overview
Problem
Existing connectors for electrical energy supply in rail transport are bulky, complex, and inflexible, requiring multiple sizes for different applications, leading to increased production costs and compromised electromagnetic interference resistance due to aging sealing issues.
Innovation Solution
A compact connector assembly with a locking device, adapters, and a sealing apparatus that includes a release protection component, foolproof device, and guide device, allowing for flexible use across various applications while enhancing electromagnetic shielding and preventing incorrect fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a connector is designed with a compact structure and modular components, then the volume and quantity of components are reduced, but the complexity of ensuring reliable locking and sealing increases
Solution Approach 1:
The connector is divided into modular components: a first connector, a second connector, and an optional adapter. Each component has a housing forming an installation space with contact terminals. This segmentation allows for compact design while maintaining functionality through standardized interfaces and locking mechanisms between modules.
Solution Approach 2:
The adapter can be arranged between the first and second connectors, with its installation space connected to both adjacent connectors. This nesting capability allows flexible configuration where smaller components fit within or between larger ones, reducing overall system volume while providing multiple connection options.
2Adaptability or versatility
If multiple connector sizes are used for different electrical power applications, then adaptability is improved, but production costs increase and modular production is prevented
Solution Approach 1:
The connector assembly provides universal adaptability through standardized housings and interfaces that work across different electrical power applications. The optional adapter enables the same basic connector design to serve multiple functions and connection scenarios, eliminating the need for entirely different connector sizes while maintaining versatility through configuration rather than redesign.
3Reliability
If the sealing device is designed for good EMI resistance, then electromagnetic compatibility is improved, but the sealing device ages and performance deteriorates
Solution Approach 1:
The locking device includes a release protection component and an insert that engage with each other before the connectors are fully mated. This preliminary engagement ensures proper alignment and prevents premature wear or deformation of sealing elements, cushioning against conditions that would accelerate aging and maintain EMI resistance throughout the service life.
Solution Approach 2:
The release protection component remains connected to one connector while separated from the other when connectors are apart, and automatically engages with the insert when connectors are combined. This self-regulating mechanism ensures consistent sealing contact and protects against misalignment without requiring external adjustment, maintaining sealing performance over time.
4Reliability
If a locking device is added to ensure reliable connection, then connection reliability is improved, but the device complexity and mounting complexity increase
Solution Approach 1:
The locking function is merged into the basic connector structure through the release protection component and insert arrangement. These elements are integrated with the housing and contact terminal assembly rather than being separate add-on components, providing reliable locking while minimizing additional complexity. The same structural elements serve both mechanical support and locking functions.
Data Source
AI summary
A connector assembly comprises: a first connector, which has a housing forming an installation space and has a contact terminal accommodated in the installation space; a second connector, which has a housing forming an installation space and has a contact terminal accommodated in the installation space; and a locking device, by means of which the first and second connectors are locked while they are joined together. The locking device comprises a release protection component on either the first connector or the second connector and an insert on the other of the components first connector and second connector. The disclosure further relates to an adapter, a connector, a lateral locking device and a mounting frame for the connector assembly. The connector assembly is easy to assemble, allows the entire device to be made compact, and has improved electromagnetic shielding and watertightness.