Miniaturized Multi-Pole Plug Connector for High Current
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Solution Overview
Problem
Existing multi-pole plug-in connection units for three-phase AC systems are not miniaturized enough to efficiently transmit high voltage and current while maintaining buckling-proof and locking mechanisms, and they are often costly to produce.
Innovation Solution
A miniaturized circular connector module with complementary plug-in connection parts and a locking sleeve, featuring a monolithic insulating body with axially latched electrical plug contacts, and a protective sheathing with strain relief, allowing for high energy transmission with a diameter less than 23 mm, and including additional auxiliary contacts and a protective conductor contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the plug-in connection unit is miniaturized to reduce size, then the diameter is reduced to less than 23 mm, but the ability to transmit high voltage and current is compromised
Solution Approach 1:
The electrical plug contacts are segmented into multiple individual contacts (three main contacts for 630V/16A and two auxiliary contacts for 63V/10A), allowing parallel current paths that increase total power transmission capacity within the miniaturized housing. This segmentation enables the connector to handle high power loads despite the reduced overall diameter of less than 23 mm.
2Device complexity
If the plug-in connection parts are made as monolithic insulating bodies, then manufacturing complexity is reduced, but the precision of contact alignment and locking reliability may be compromised
Solution Approach 1:
The electrical plug contacts are pre-positioned and fixed within the monolithic insulating body during the injection molding process. This preliminary positioning ensures precise alignment of complementary contacts from opposing connectors before the actual plugging operation, maintaining high manufacturing precision while using a simple monolithic structure that reduces overall device complexity.
3Reliability
If the locking sleeve is added to secure the plug-in connection parts, then connection reliability is improved, but the device complexity and production cost increase
Solution Approach 1:
The locking sleeve is merged with the monolithic insulating body structure, where the sleeve integrates with the insulator housing rather than being a completely separate component. This merging approach provides reliable locking functionality through the bayonet-style locking mechanism while minimizing the increase in device complexity and production cost, as the locking features are incorporated into the existing structural framework.
4Object-affected harmful factors
If the protective sheathing with strain relief is added, then protection against environmental factors is improved, but manufacturing complexity increases
Solution Approach 1:
The protective sheathing is implemented as a flexible protective coating or thin film layer that envelops the insulating body and cable assembly. This flexible shell provides dustproof and watertight protection (IP65 rating) while being applied through a relatively simple process such as injection molding or coating, thus improving environmental protection without significantly increasing manufacturing complexity.
Data Source
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AI summary
A multi-pole plug connection unit for three-phase alternating current systems having two plug connection parts which complement one another for the purpose of kink-free plug connection and having a locking sleeve which axially secures the plug connection parts in relation to one another in the plug-connected state is known. According to the invention, each plug connection part is constructed as a monolithic insulating body in which a plurality of electrical plug contacts are axially latched, and an outside diameter of the plug connection parts and the locking sleeve is less than 23 mm, and the plug connection unit is designed to transmit voltage and current intensity ranges of up to 630 volts/16 amperes. Said multi-pole plug connection unit is used for energy and signal transmission in machine tools.