Displaceable Module Connector for Positional Deviation Compensation
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Solution Overview
Problem
Existing module connectors are unable to compensate for positional deviations between electric modules, leading to potential electrical and mechanical connection issues.
Innovation Solution
A module connector with displaceable contact assemblies and a conductor assembly housed in an electrically insulating material, allowing for force-free adjustment to accommodate varying distances between electric modules, using a U-shaped power rail and telescopic housing parts to ensure secure and gap-free connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If module connectors are designed with fixed contact assemblies, then manufacturing precision is improved, but adaptability deteriorates because they cannot compensate for positional deviations between electric modules
Solution Approach 1:
The contact assembly is designed with a displaceable contact element that can move relative to the conductor assembly along a guide path. This dynamic structure allows the contact element to adjust its position to compensate for deviations in the distance between electric modules, while the overall connector structure remains manufacturable with standard tolerances
Solution Approach 2:
The contact assembly is segmented into a conductor assembly and a displaceable contact element. This segmentation allows the contact element to be independently positioned and adjusted relative to the conductor assembly, enabling compensation for positional deviations without requiring the entire connector to be custom-manufactured
2Adaptability or versatility
If module connectors allow for positional adjustment, then adaptability is improved, but device complexity increases due to additional displaceable components
Solution Approach 1:
The contact element is designed to be displaceable along a simple linear guide path defined by the housing and conductor assembly. This dynamic capability is achieved through a straightforward mechanical guide structure rather than complex actuators or mechanisms, maintaining simplicity while enabling adaptability
Solution Approach 2:
The contact element serves multiple functions: it provides electrical contact, allows for positional adjustment, and compensates for manufacturing tolerances. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity
3Reliability
If contact assemblies are made displaceable, then reliability is improved by preventing forced connections, but manufacturing complexity increases
Solution Approach 1:
The contact element can displace along a guide path to accommodate distance variations, preventing forced connections and improving reliability. The guide path is integrated into the housing and conductor assembly design, avoiding the need for separate adjustment mechanisms
Solution Approach 2:
The contact element automatically positions itself along the guide path to achieve proper contact alignment. This self-adjusting capability improves reliability by preventing forced connections while requiring minimal additional manufacturing complexity, as the guide path structure serves both as a mechanical guide and a positioning feature
Data Source
AI summary
A module connector for electrically connecting a pair of electric modules includes a pair of contact assemblies spaced from one another and fastening the module connector to the electric modules, a conductor assembly electrically connecting the contact assemblies and, with the contact assemblies, forming an electrical connection between the electric modules, and a housing formed of an electrically insulating material. The contact assemblies and the conductor assembly are accommodated in the housing. At least one of the contact assemblies is fastened to the conductor assembly in a manner displaceable relative to the conductor assembly in a direction of displacement directed towards and/or away from the other of the contact assemblies.