Plug Connection Self-Centering Curved Contact Interface
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Solution Overview
Problem
Existing plug connections for high-current lines in motor vehicles require precise alignment, making handling difficult and increasing the risk of flashover during plugging or unplugging, which can lead to injury and component damage.
Innovation Solution
A plug connection design featuring a first contact part with a part-spherical end face and a second contact part with a trumpet-shaped depression, allowing for self-centering and axial spring-loading, eliminating the need for additional safety components and enabling hot-pluggable functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact parts are designed as simple contact pins and contact sockets requiring precise alignment, then contact reliability is improved, but handling difficulty increases and device complexity increases due to additional safety components
Solution Approach 1:
The first contact part is designed with a part-spherical end face and the second contact part has a trumpet-shaped depression, creating a curved geometric interface that enables self-centering during insertion. This curvature allows the connectors to automatically align themselves, eliminating the need for precise manual alignment while maintaining reliable contact.
Solution Approach 2:
The special configuration of the end faces enables self-centering functionality, where the connectors automatically align and center themselves during the plugging process without requiring external alignment mechanisms or precise manual positioning by the operator.
2Reliability
If precise alignment is required for plug connectors, then contact reliability is improved, but the risk of flashover during plugging or unplugging increases
Solution Approach 1:
The curved geometric interface with the part-spherical end face and trumpet-shaped depression ensures that contact is established gradually during insertion, with the self-centering action distributing the contact force and reducing the risk of sudden flashover that can occur with misaligned simple pin-socket connections.
3Reliability
If additional safety components are integrated into connectors, then safety functionality is improved, but device complexity increases
Solution Approach 1:
The invention extracts and eliminates the need for additional safety components such as interlocks and complex alignment mechanisms by incorporating safety functionality directly into the basic geometric design of the contact parts themselves, thereby reducing overall device complexity.
Solution Approach 2:
The special end face configuration serves multiple functions simultaneously: it provides self-centering for easy handling, ensures reliable contact alignment, and reduces flashover risk, thereby eliminating the need for separate dedicated safety 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
The design ensures reliable contact despite non-coaxial or non-parallel alignment, reduces the risk of flashover, and simplifies handling while maintaining contact reliability and safety in high-voltage applications.
Implementation Method 1
the contact parts being in the plugged-in state of the connector spring-loaded axially
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a plug connection comprising a first plug (1) that includes a first contact piece (4), and a second plug (2) that includes a second contact piece (5). In the plugged state of the plug connection, the contact pieces (4, 5) are axially in contact with one another in a spring-biased manner. The first contact piece has a three-dimensionally curved end face (7), while the second contact piece has a flaring depression (8) in the end face thereof such that an annular contact zone is formed between the contact pieces (4, 5).