Modular Connector Plug With Add-On Modules
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Solution Overview
Problem
Existing connector plug systems require a large number of different connectors to accommodate varying test requirements, leading to complex and costly assembly and disassembly processes, especially when replacing worn parts.
Innovation Solution
A modular connector plug system comprising a base module with cable connection and plug contacts, along with add-on modules that can be mechanically and electrically connected to increase the number of contacts, featuring a secure locking mechanism and made from plastic components for cost-effective assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modular plug-in connectors are assembled by screw connections, then the number of contacts can be adjusted, but the assembly process becomes laborious and complex
Solution Approach 1:
The connector is divided into a base module and multiple add-on modules, each with standardized connection interfaces. This segmentation allows flexible configuration of contact numbers by combining different numbers of modules, while each module maintains simple internal structure for easy assembly
Solution Approach 2:
All modules (base and add-on) use identical connection interfaces and locking mechanisms. This universal design enables any module to be assembled with any other module using the same simple procedure, achieving adaptability without increasing assembly complexity
2Ease of repair
If modular connectors are disassembled to replace worn parts, then maintenance is possible, but the disassembly process becomes complex
Solution Approach 1:
The connector is segmented into independent modules that can be individually removed. When a part wears out, only the specific module containing that part needs to be disassembled and replaced, not the entire connector, simplifying the repair process
Solution Approach 2:
The locking mechanism uses movable locking elements (lugs and recesses) that can be easily engaged and disengaged. This dynamic locking system allows quick module replacement without complex tools or procedures, facilitating easy maintenance
3Adaptability or versatility
If a large number of different connectors are provided for different test requirements, then test specifications are met, but financial and logistical expenditures increase
Solution Approach 1:
Instead of maintaining multiple different connector types, a universal base module design with standardized interfaces allows the same physical connector to be configured for different test requirements by adding or removing add-on modules. This reduces the total number of connectors needed while maintaining versatility
Solution Approach 2:
The connector configuration is dynamic rather than fixed. Modules can be added or removed to adapt the connector to different test specifications, allowing one physical connector to serve multiple functions that previously required multiple different connectors
Data Source
AI summary
A variable plug of a connector has a modular construction and includes a base module with cable connection and plug contacts. Depending on the desired total number of contacts of the plug, one or more add-on modules having additional plug contacts can be mechanically and electrically connected with the base module.