Rail-Mounted Module Interconnector for Secure Wire-Free Coupling
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Solution Overview
Problem
Existing electrical module interconnection systems are inadequate for secure mechanical and electrical connections, leading to disengagement and loss of connectivity.
Innovation Solution
A system using an interconnector with slotted ports and contact pads to align and connect electrical modules, ensuring stable power and data transmission without additional wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If sliding interconnection mechanisms are used to reduce wires, then the amount of wiring is reduced, but the mechanical connection strength is insufficient and modules are prone to disengagement
Solution Approach 1:
The interconnector is divided into two separate portions that can be independently inserted into slotted ports on adjacent modules. This segmentation allows each portion to be securely received by its own slotted port, providing both mechanical strength and electrical connection without requiring extensive wiring throughout the entire module assembly.
Solution Approach 2:
The interconnector serves as an intermediary component between adjacent electrical modules, providing both mechanical coupling and electrical interconnection. By inserting the interconnector portions into slotted ports, it mediates the connection between modules, replacing the need for direct wiring between them while ensuring secure mechanical attachment.
2Reliability
If traditional wiring is used to connect modules, then reliable electrical connection is achieved, but the complexity of installation and servicing increases
Solution Approach 1:
The interconnector merges mechanical connection and electrical connection functions into a single component. By combining these two functions, the system eliminates the need for separate wiring harnesses and connection mechanisms, thereby reducing installation complexity while maintaining reliable electrical connection between modules.
Solution Approach 2:
The interconnector is designed with multi-functionality, serving both as a mechanical coupling device and an electrical connector. This universal component can be used to interconnect adjacent modules in various configurations, reducing the need for different specialized components and simplifying the overall system architecture.
3Adaptability or versatility
If modules are mounted side-by-side on a rail, then flexible system design is enabled, but secure mechanical interconnection between adjacent modules is difficult to achieve
Solution Approach 1:
The slotted ports are positioned at specific locations on the module housing to receive the interconnector portions. This local placement provides targeted mechanical engagement points that ensure secure interconnection between adjacent modules while maintaining the overall flexible side-by-side mounting configuration on the rail.
Solution Approach 2:
The interconnector extends in a dimension perpendicular to the rail mounting plane, creating a three-dimensional connection structure. By utilizing this additional dimension, the interconnector can securely engage with slotted ports on adjacent modules without interfering with the side-by-side rail mounting arrangement, thereby maintaining design flexibility while achieving strong mechanical interconnection.
Data Source
AI summary
Systems, methods, and modes for mechanically and electrically interconnecting a plurality of electrical modules mounted on a rail side by side via an interconnector. Each electrical module comprises a housing and at least one slotted port recessed in the housing having a plurality of electrical contact pins therein. The interconnector comprises a first portion and a second portion each having a plurality of electrical contact pads, wherein each contact pad in the first portion is electrically connected to respective one of the plurality of contract pads in the second portion. The interconnector is adapted to removably attach to the electrical modules by inserting the first and second portions into respective slotted ports in the electrical modules and thereby aligning and electrically connecting the contact pads of the interconnector with respective contact pins of the electrical modules.