Piezoelectric Plug-in Cycle Counter in Electric Connectors
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Solution Overview
Problem
Existing electrical connectors with plug-in cycle counters face challenges in achieving high functional reliability while being cost-effective, as they require additional design effort and are prone to malfunctions beyond a predetermined number of mating cycles.
Innovation Solution
The integration of a piezoelectric sensor within the connector's contact structure, which generates an electrical impulse upon contact force application, allowing for reliable detection of plug-in cycles through elastic deformation, and an evaluation unit with a memory module for tracking and displaying cycle counts, optionally using an RFID tag for energy supply and output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical counter or additional counting device is integrated into the connector, then the mating cycle can be counted, but the device complexity increases and manufacturing costs rise
Solution Approach 1:
The piezoelectric sensor is integrated directly into the contact structure of the connector, merging the counting function with the existing mechanical components. The sensor utilizes the contact force already present during mating operations to generate counting signals, eliminating the need for separate counting mechanisms and reducing overall device complexity.
Solution Approach 2:
The contact structure serves dual purposes: it establishes electrical contact and simultaneously acts as a force transmission element for the piezoelectric sensor. The same mechanical interaction that creates the electrical connection also generates the counting signal, making the connector structure multi-functional and avoiding additional components.
2Reliability
If a piezoelectric sensor is integrated into the contact structure, then the mating cycle detection becomes more reliable, but the manufacturing precision requirements increase
Solution Approach 1:
The piezoelectric sensor is pre-integrated into the contact structure during connector manufacturing, with the sensor positioned to receive contact force before the actual mating operation occurs. This preliminary integration ensures that the sensor is properly aligned and positioned, reducing the need for high-precision adjustments during assembly and lowering manufacturing precision requirements.
Solution Approach 2:
The contact structure itself serves to position and support the piezoelectric sensor through its inherent mechanical geometry. The sensor is mechanically coupled to the contact elements in such a way that the normal mating forces automatically position the sensor correctly, eliminating the need for additional precision alignment features or complex mounting structures.
3Reliability
If an evaluation unit with memory module is added to track and display cycle counts, then the cycle limit monitoring is improved, but the device complexity and cost increase
Solution Approach 1:
The evaluation unit is powered directly by the electrical impulses generated from the piezoelectric sensor during mating operations. The sensor's output signal serves dual purposes: it triggers the counting function and simultaneously provides power to the evaluation unit and memory module, eliminating the need for separate power sources and reducing overall system complexity.
Solution Approach 2:
The evaluation unit, memory module, and display functionality are integrated into a single compact circuit board or module that is embedded within the connector housing. This consolidation merges multiple functions into one unit, reducing the overall device complexity and minimizing the space required for additional components.
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
This solution enhances the reliability and cost-effectiveness of plug-in cycle counting by ensuring consistent contact force application, reducing the need for external power sources, and providing direct feedback on cycle limits, thus preventing connector malfunctions.
Implementation Method 1
The integration of a piezoelectric sensor within the connector's contact structure, which generates an electrical impulse upon contact force application, allowing for reliable detection of plug-in cycles through elastic deformation
Data Source
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AI summary
The invention relates to an electric plug connector (18a, 18b) having a contact structure (11, 12) accommodated in a housing (13a, 13b), and a plug-in cycle counter. According to the invention, the plug-in cycle counter has a piezoelectric crystal (15a, 15b), by means of which forces occurring during the plug-in operation can be detected in order to register a plug-in cycle. Advantageously, the piezoelectric transmitter (15a, 15b) can also be used as a power supply for the operation of an evaluation unit (17a, 17b) which is integrated into the plug connector (18a, 18b) and which can therefore be operated energy-autonomously. Advantageously, reliable operation associated with a comparatively low component outlay is possible in this way. The invention further relates to a method for operating the plug connector according to the invention.