Modular Plug Connector Shape Memory Alloy Locking
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Solution Overview
Problem
Modular connectors face challenges in securely preventing unintentional disconnection, especially when high electrical currents are transmitted, which can lead to hazardous electric arcs and system failures, and existing solutions require complex locking mechanisms or expensive materials.
Innovation Solution
A modular connector with a locking device that uses a shape memory alloy element to transition between locking and release states based on temperature changes, ensuring the connection remains secure without external complex locking mechanisms or expensive materials, and can be integrated into existing systems for secure automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex locking brackets or plug-in devices are used to secure the connection, then the connection security is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent changes the physical state of the shape memory alloy through temperature variations. When heated above the transformation temperature, the alloy transitions from martensite to austenite phase, enabling it to exert locking force. When cooled below the transformation temperature, it transitions back to martensite phase, releasing the lock. This parameter change (temperature) controls the locking mechanism without complex mechanical structures.
Solution Approach 2:
The patent replaces traditional mechanical locking systems (locking brackets, plug-in devices) with a thermally-actuated shape memory alloy system. The locking force is generated by the phase transformation of the material itself rather than through mechanical interlocking components, significantly simplifying the device structure.
2Reliability
If traditional locking mechanisms are used to prevent unintentional disconnection, then the connection security is improved, but the installation space required increases
Solution Approach 1:
The patent merges the locking function with the connector body by integrating the shape memory alloy element directly into the connector structure. The shape memory alloy serves dual purposes: it provides the locking mechanism and is structurally integrated into the connector housing, eliminating the need for separate locking components and reducing overall installation space.
Solution Approach 2:
The locking mechanism utilizes temperature parameter changes to activate the shape memory alloy, allowing a compact design that doesn't require additional space for mechanical actuators or complex locking structures. The thermal field replaces the need for mechanical activation space.
3Device complexity
If shape memory alloy is used for locking, then the device complexity is reduced, but the temperature control requirements increase
Solution Approach 1:
The patent converts the potentially harmful effect of high temperatures (which could cause unwanted locking) into a beneficial feature. The high transformation temperature ensures that normal operational heat from current flow or environmental conditions Ta does not trigger locking, while still allowing intentional activation when needed. The temperature threshold becomes a safety feature rather than a control challenge.
Solution Approach 2:
The high transformation temperature acts as a preliminary protective measure against unintentional locking during normal operation. By setting the transformation temperature above typical operational temperatures, the system pre-prevents accidental activation, ensuring that locking only occurs when deliberately triggered by controlled heating.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents unintentional disconnection and reduces the risk of electric arcs, enhancing personal safety and power quality while minimizing costs and space requirements, allowing for secure automation in various technical applications.
Implementation Method 1
A modular connector with a locking device that uses a shape memory alloy element to transition between locking and release states based on temperature changes
Data Source
Figure 1A
Figure 1B~1D
Figure 2A~2B
AI summary
The invention relates to a modular plug connector (10) which has a plug (12) comprising a plurality of plug modules (14) and has a mating plug (16) comprising a plurality of mating plug modules (18), in which plug connector each plug module (14) forms a plug module pair (20, 21) with a mating plug module (18), wherein the plug (12) and the mating plug (16) can assume an interconnected state and wherein at least one of the plug module pairs (20, 21) has at least one locking device (22), which can assume a locking state (24) in the connected state of the plug (12) and the mating plug (16), in which locking state the locking device prevents the plug module (14) and the mating plug module (18) of said plug module pair (20, 21) from separating from each other.