Modular Electrical Plug Device for Magnet Coil Connection

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Solution Overview

Problem

Existing electrical plug devices for magnet coils and sensor elements in high-pressure fuel pumps require type-specific designs for each contact partner, leading to increased production costs and complexity, especially in the automotive industry where identical modules must fit different counterpieces.

Innovation Solution

An electrical plug device comprising a first portion with a magnet coil or sensor element and an electrical contact element, non-detachably interconnected, and a second portion produced separately in a type-specific manner to match the counterpiece, allowing for cost-effective and modular production by simplifying injection-molding processes and reducing tooling costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a type-specific design is used for each contact partner, then the electrical plug device can be precisely adapted to the counterpiece, but the production cost and device complexity increase

Engineering Contradiction:

Improveadaptation to counterpieceVSAvoidproduction complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electrical plug device is divided into two distinct portions: a type-unspecific first portion containing the magnet coil, sensor element, and contact element, and a type-specific second portion that is separately produced and subsequently joined to the first portion. This segmentation allows the first portion to be produced in a standardized manner while the second portion is customized for different counterpieces, thereby reducing overall production complexity while maintaining adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first portion of the electrical plug device is designed as a universal component that can be used with multiple different counterpieces. By making the magnet coil, sensor element, and contact element type-unspecific, this portion serves multiple functions across different applications, reducing the need for completely custom designs for each counterpiece and thereby lowering production costs and complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If a type-specific design is used for each contact partner, then the electrical plug device can be precisely adapted to the counterpiece, but the production cost increases

Engineering Contradiction:

Improveadaptation to counterpieceVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If the entire electrical plug device is produced as a single integrated component, then the production process is simpler, but the adaptability to different counterpieces is reduced

Engineering Contradiction:

Improveproduction simplicityVSAvoidadaptation to counterpiece

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If type-specific designs are produced for each counterpiece, then the adaptation precision is improved, but the development time and tooling costs increase

Engineering Contradiction:

Improvetype-specific fitVSAvoiddevelopment time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first portion of the electrical plug device is produced in advance as a standardized component, ready for assembly with different second portions. This preliminary production of the universal first portion reduces development time and tooling costs, as the same first portion can be reused across multiple applications with only the second portion needing customization for each specific counterpiece.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9577363B2Electrical plug device for connection of a magnet coil and/or of a sensor element

Publication Date: 2017.02.21 ROBERT BOSCH GMBH

AI summary

An electrical plug device is configured for the connection of a magnet coil and/or of a sensor element to a contact partner of a counterpiece cooperating with the electrical plug device. The electrical plug device has at least one first portion, which comprises the magnet coil and/or the sensor element and at least one electrical contact element. The magnet coil and/or the sensor element and the at least one electrical contact element of the first portion are non-detachably interconnected. The electrical plug device also has a second portion, which is produced separately from the first portion and is type-specific in relation to the counterpiece. The second portion is joined to the first portion and surrounds the electrical contact element, at least in part.