Modular Connector Assembly with Movable Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical connector systems face issues with excess slack cable complexity, misalignment accommodation, and high manual effort due to fixed monolithic block structures and cable harnesses, which can lead to connector damage and signal interference.
Innovation Solution
A modular connector assembly with movable modules that allow independent mating of electrical devices, reducing insertion forces and accommodating misalignment, while maintaining a compact design without external cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable harnesses are used to electrically connect adjacent electrical devices, then the devices can be connected, but excess slack cable adds complexity and interferes with other components
Solution Approach 1:
The connector assembly is divided into multiple separate modules (first module, second module, third module) that can be independently positioned and mated. Each module contains its own connectors and is electrically connected to adjacent electrical devices, eliminating the need for long slack cables while maintaining electrical connectivity.
Solution Approach 2:
The connector modules are arranged in a vertical stacking configuration along a longitudinal axis, utilizing the vertical dimension to connect adjacent electrical devices. This vertical arrangement eliminates horizontal cable slack while providing structured electrical pathways between devices.
2Stability of the object's composition
If monolithic block structures with fixed connectors are used, then all connectors are held in fixed position, but the structure cannot accommodate misalignment of electrical devices
Solution Approach 1:
The connector modules are designed with movable characteristics, allowing them to be independently positioned and adjusted relative to each other along the longitudinal axis. This dynamic positioning capability enables the modules to accommodate misalignment between electrical devices while maintaining stable electrical connections.
Solution Approach 2:
By separating the connector assembly into multiple independent modules rather than a single fixed monolithic structure, each module can be independently positioned to accommodate misalignment. The modules maintain relative stability through their mechanical coupling while allowing positional adjustment.
3Stability of the object's composition
If monolithic block structures are used, then connectors are fixed in position, but high insertion forces are needed to mate all connectors simultaneously
Solution Approach 1:
The connector assembly is segmented into multiple modules that can be mated to electrical devices in sequence rather than all at once. This reduces the insertion force required at any given time, as only a portion of the total connectors need to be mated simultaneously, while the modules remain mechanically coupled for stability.
Solution Approach 2:
The modules are designed to be movable relative to each other, allowing sequential mating operations. This dynamic capability enables the system to reduce peak insertion forces by distributing the mating process across multiple steps, while maintaining stable connections once mated.
4Ease of operation
If modules are made movable relative to each other to allow separate mating, then insertion forces are reduced and misalignment is accommodated, but the mechanical coupling must maintain electrical connectivity
Solution Approach 1:
The mechanical coupling between modules is combined with electrical connectivity functions. The modules are mechanically coupled to each other along the longitudinal axis, and this same mechanical connection provides the electrical pathway between adjacent electrical devices, eliminating the need for separate cable connections.
Solution Approach 2:
The system is segmented into electrically connected modules that maintain both mechanical coupling and electrical connectivity. Each module contains connectors that mate with electrical devices, and the modules are electrically connected to each other through their mechanical coupling, ensuring reliable electrical pathways even as modules move independently.
Data Source
AI summary
A connector assembly includes a first module and a second module. Each of the first and second modules extends parallel to a longitudinal axis between a respective front end and a respective rear end opposite the front end. Each of the first and second modules includes a respective shell and one or more electrical connectors held by the shell and exposed at the respective front end for mating to a corresponding mating electrical device. The shell of the second module is mechanically coupled to the shell of the first module between the front and rear ends of the first module. The second module is movable relative to the first module parallel to the longitudinal axis to allow for separately mating the first and second modules to the corresponding mating electrical devices.