Plug Connector Protective Collar Latching Mechanism
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Solution Overview
Problem
Existing plug connections in automotive engineering face challenges in ensuring a permanent yet detachable connection under operational and assembly stresses, requiring precise alignment and reliable assembly processes that are often split across different manufacturing companies.
Innovation Solution
The plug connection features a protective collar and contact carrier with latching means that allow the collar to be pre-latched, then shifted and locked into place only when the contact carrier is fully plugged into the socket, enabling separate manufacturing and assembly of components, with the collar being captively arranged and requiring minimal force for final locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protective collar is permanently fixed to the contact carrier, then the connection reliability is improved, but the assembly flexibility and ease of manufacture are worsened
Solution Approach 1:
The latching mechanism is divided into two independent stages: pre-latching (between protective collar and contact carrier) and final latching (between contact carrier and socket). This segmentation allows the protective collar to be manufactured and pre-assembled with the contact carrier in one facility, while the final assembly with the socket occurs in another facility, thereby maintaining both connection reliability and assembly flexibility.
Solution Approach 2:
The protective collar is pre-latched to the contact carrier before the final assembly with the socket. This preliminary action ensures that the protective collar is securely attached during transport and handling, while still allowing for the final latching operation to occur at the appropriate time and location, resolving the contradiction between permanent fixation and assembly flexibility.
2Strength
If high assembly forces are required to ensure secure connection, then the connection strength is improved, but the ease of operation and risk of damage are worsened
Solution Approach 1:
The latching mechanism transitions from a static high-force requirement to a dynamic two-stage process. The pre-latching stage uses minimal force to secure the protective collar to the contact carrier, while the final latching stage engages additional latching means only when the contact carrier is properly positioned in the socket, distributing the locking action throughout the assembly process and reducing peak forces required.
Solution Approach 2:
The pre-latching of the protective collar to the contact carrier prepares the assembly for final insertion, ensuring proper alignment and reducing the force needed during final assembly. This preliminary positioning action prevents misalignment that would otherwise require excessive force to correct.
3Ease of operation
If the protective collar is loosely attached to allow easy assembly, then the ease of operation is improved, but the reliability of the connection is worsened
Solution Approach 1:
The latching system is segmented into two independent but sequential stages: pre-latching provides initial secure attachment with easy engagement, while final latching provides additional security when the contact carrier is fully inserted. This segmentation ensures both ease of assembly and connection reliability without requiring the protective collar to be either loosely attached or difficult to assemble.
Solution Approach 2:
The latching mechanism dynamically adapts its securing force based on the assembly stage. During initial assembly, the pre-latching means engage with minimal force for easy operation. Once the contact carrier is fully inserted and positioned, the final latching means engage to provide enhanced security, thereby achieving both ease of operation and connection reliability.
Data Source
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AI summary
The plug connector (1) has a plug with a plug-in header (4) and a coupler brought in active connection with the plug connection. A protective shroud (2), a contact carrier (3) and the plug-in header have an engagement unit brought in active connection with one another such that the protective shroud is brought into engagement position with the contact carrier. The contact carrier is plugged together with the protective shroud and after fully plugging the protective shroud is shifted in the direction of the plug-in header and engages there in an end position.