Modular Connector Housing for Flexible Rail Cable Assembly
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Solution Overview
Problem
Existing connectors for rail vehicles are heavy, voluminous, and require multiple units to meet diverse application needs, complicating installation and failing to prevent environmental factors like rain, snow, and dust accumulation.
Innovation Solution
A multiple-combination connector design featuring a housing with interchangeable sockets and plugs, incorporating poka-yoke mechanisms for correct insertion, stainless steel threaded inserts for durability, and a streamlined shape to prevent powder spraying and enhance EMC and IP ratings, allowing for flexible configuration and easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple plugs are integrated into a single connector unit, then the connector can meet diverse application requirements, but the weight and volume of the connector increase significantly
Solution Approach 1:
The connector is divided into a base unit with socket and a separate plug that can be independently attached and detached. This segmentation allows the plug to be added only when needed, rather than integrating multiple plugs into a single heavy unit, thus reducing the base connector weight while maintaining versatility through combination.
Solution Approach 2:
The base connector unit with socket is designed as a universal platform that can accommodate different types of plugs through standardized interfaces and coding mechanisms. This multi-functionality allows a single base unit to serve diverse application requirements by simply changing the attached plug, eliminating the need for multiple separate connector units.
2Adaptability or versatility
If multiple plugs are integrated into a single connector unit, then the connector can meet diverse application requirements, but the volume of the connector increases
Solution Approach 1:
By segmenting the connector into a compact base unit and a separate plug, the base unit volume is minimized to only what is necessary for the socket and mounting structure. The plug adds volume only when actually attached and needed, rather than permanently increasing the connector volume through integration of multiple plugs.
Solution Approach 2:
The plug is designed to nest into or attach to the base connector unit, with the plug's flange fitting over the socket's flange. This nesting arrangement allows the components to occupy shared space when combined, reducing the overall volume compared to having multiple separate connector units or a large integrated housing.
3Adaptability or versatility
If a plurality of connectors are provided to meet different application requirements, then different current strength and cable quantity requirements can be satisfied, but the complexity of installation and management increases
Solution Approach 1:
The base connector unit with socket serves as a universal mounting platform that can accommodate different plug types through standardized interfaces. This universality allows a single base unit to replace multiple specialized connectors, simplifying installation and management while still meeting different current strength and cable quantity requirements through plug selection.
Solution Approach 2:
Coding pins and coding pin holes are strategically positioned at asymmetric locations on the plug and socket flanges to prevent incorrect insertion. This asymmetric coding mechanism ensures that only compatible plugs can be attached to the socket, providing guidance and prevention of errors without requiring complex alignment procedures or multiple different connector types.
4Strength
If traditional connector designs are used, then structural strength can be maintained, but the connector becomes vulnerable to environmental factors like rain, snow, and dust accumulation
Solution Approach 1:
The flange of the plug and socket are designed with curved outer peripheries instead of sharp angles or flat surfaces. This spheroidal or rounded shape prevents rain, snow, ice, and dust from accumulating in corners or crevices, as water and debris naturally shed from curved surfaces. The curved design maintains structural strength while effectively preventing environmental factor accumulation.
Data Source
AI summary
A multiple-combination connector includes a housing which is formed by a lower housing and a matching upper housing. The lower housing has at least one opening. At least one socket is attached to the opening. A plurality of individual plugs which can be independently inserted into the socket. The connector can bring about a flexible combination of different types and different numbers of plugs/sockets and meet different application requirements. Since the design is that of a single plug, it is possible to assemble and disassemble the cables one by one, thereby facilitating assembly. The connector can prevent incorrect insertion and withstand disassembly and assembly. The problem of powder spraying is easily solved. The EMC functions, Ingress Protection (waterproof and dustproof) functions and protective earthing functions are implemented. The accumulation of rain, snow, ice and dust is effectively prevented, and small size and easy installation are achieved.