Electrical Plug Connector Assembly Without Rotational Alignment
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Solution Overview
Problem
Existing electrical plug connectors require precise azimuthal or rotational orientation during assembly, which can be difficult and time-consuming, often leading to damage to terminals and wires.
Innovation Solution
A connector design featuring a housing with defined receiving spaces, a conductive electrical connecting element, a retaining element, and a contact-securing insert, allowing for axial fixation of the connecting element within the housing, independent of azimuthal orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a specific azimuthal or rotational orientation of the terminal is required during insertion, then the connector achieves proper assembly, but the assembly process becomes difficult and time-consuming
Solution Approach 1:
The patent applies asymmetry by providing at least one asymmetric marking on the housing and at least one corresponding asymmetric marking on the terminal. These asymmetric markings guide the operator to insert the terminal in the correct orientation, eliminating the need for complex alignment procedures while ensuring proper assembly. The asymmetric features create an obvious visual cue that simplifies the assembly process.
Solution Approach 2:
The patent implements preliminary action by pre-configuring the housing and terminal with integrated asymmetric markings during manufacturing. This pre-prepared guidance system is already in place before assembly begins, eliminating the need for complex alignment procedures during the assembly process itself. The markings are built-in features that automatically guide correct orientation.
2Manufacturing precision
If a specific azimuthal or rotational orientation of the terminal is required during insertion, then the connector achieves proper assembly, but damage to terminals and wires occurs
Solution Approach 1:
The asymmetric markings on the housing and terminal provide clear visual guidance for correct insertion orientation. This prevents operators from forcing terminals into incorrect orientations, which would otherwise cause damage to the terminals and associated wires. The asymmetric features make the correct orientation obvious and eliminate guessing or trial-and-error insertion attempts.
Solution Approach 2:
By pre-configuring the asymmetric markings during manufacturing, the patent ensures that the guidance system is already in place before assembly. This preliminary preparation prevents damage during the assembly process by guiding operators to insert terminals in the correct orientation from the start, avoiding forced insertion and potential damage to delicate terminal and wire components.
3Manufacturing precision
If complex alignment procedures are used to achieve proper orientation, then assembly precision is improved, but assembly complexity increases
Solution Approach 1:
The patent replaces complex alignment procedures with simple asymmetric markings on the housing and terminal. These markings provide intuitive visual guidance that eliminates the need for complex alignment steps, special tools, or multiple adjustment operations. The asymmetric features create an obvious visual cue that simplifies the assembly procedure while maintaining high assembly precision.
Solution Approach 2:
The patent incorporates alignment guidance features directly into the housing and terminal structures during manufacturing. This preliminary integration of alignment markings eliminates the need for separate alignment procedures, special alignment tools, or complex multi-step alignment processes. The alignment function is built-in and automatic, reducing assembly procedure complexity while maintaining precision.
Data Source
AI summary
A connector includes a housing defining a first receiving space and a second receiving space, a conductive electrical connecting element arranged in the second receiving space, a retaining element engaging around at least portions of the electrical connecting element and a contact-securing insert arranged in the first receiving space. The conductive electrical connecting element includes a contact sleeve adapted to connect to a contact pin, and an electrical contact adapted to connect to an electrical conductor. The contact-securing insert fixing the electrical connecting element and the retaining element within the housing in an axial direction of the electrical connecting element.