Plug Connection End Position Fixing for Vibration Resistance

Solution Overview

Problem

Existing electrical plug connections in high-current applications, such as motor vehicles, experience relative movement between contacts and pins, leading to wear and reduced service life due to vibrations, which has not been optimally minimized by existing solutions.

Innovation Solution

A connector system with a first fixing element for locking the wiring harness connector and a second fixing element that securely attaches the wiring harness connector and/or electrical line to the unit without play, ensuring they share the same vibration level and preventing movement parallel and perpendicular to the insertion direction, thereby reducing relative movement and wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a single fixing element is used to lock the cable connector at the interface, then the connector is secured against the interface, but relative movement between the electrical contact and pin still occurs due to vibrations

Engineering Contradiction:

Improveconnection stabilityVSAvoidrelative movement and wear

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The fixing system is divided into two independent fixing elements: a first fixing element for locking the cable connector at the interface, and a second fixing element for securing the cable connector and/or line to the unit. This segmentation allows each element to address specific movement directions, preventing both connector detachment and contact-pin relative movement caused by vibrations.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If the cable connector and line are fixed directly on the unit without play, then movement parallel and perpendicular to insertion direction is prevented, but the assembly complexity increases

Engineering Contradiction:

Improvevibration resistanceVSAvoidnumber of fixing elements

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The fixing system is divided into two independent fixing elements: a first fixing element for locking the cable connector at the interface, and a second fixing element for securing the cable connector and/or line to the unit. This segmentation allows each element to address specific movement directions, preventing both connector detachment and contact-pin relative movement caused by vibrations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second fixing element acts as an intermediary that directly connects the cable connector and/or line to the unit, creating a form-fitting connection without play. This intermediary structure eliminates the need for additional complex mounting mechanisms while preventing both parallel and perpendicular movements.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If existing fixing solutions from DE 10 2004 024 530 A1 are used, then the connector can be locked, but optimal minimization of relative movement has not been achieved

Engineering Contradiction:

Improveconnector lockingVSAvoidrelative movement minimization

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The fixing system is divided into two independent fixing elements: a first fixing element for locking the cable connector at the interface, and a second fixing element for securing the cable connector and/or line to the unit. This segmentation allows each element to address specific movement directions, preventing both connector detachment and contact-pin relative movement caused by vibrations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second fixing element acts as an intermediary that directly connects the cable connector and/or line to the unit, creating a form-fitting connection without play. This intermediary structure eliminates the need for additional complex mounting mechanisms while preventing both parallel and perpendicular movements.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP3028349B1End position fixing of a plug connection for increasing the vibration resistance

Publication Date: 2018.08.15 ROBERT BOSCH GMBH

Figure 1A
Figure 1B
Figure 1C

AI summary

The invention presents a plug system (1) for high-power plug connections. The plug system (1) has a cable harness plug (3) having an electrical line (5) and an assembly (7) with an interface (9) for establishing an electrical connection between the cable harness plug (3) and the assembly (7). The plug system (1) also has a first fixing element (11) for fixing the cable harness plug (3) to the interface (9) in an interlocking manner. The plug system (1) furthermore has a second fixing element (13) which is designed to fix the cable harness plug (3) and/or the line (5) to the assembly (7) in an interlocking manner in such a way that movement of the cable harness plug (3) and/or of the line (5) parallel and perpendicular to a plugging direction (15) of the cable harness plug (3) is suppressed.