Plug Connector Guide Mechanism for Fuel Injector Mounting
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Solution Overview
Problem
The existing methods for connecting fuel injectors in internal combustion engines require oil-tight cables and complex screw connections, leading to high mounting efforts and costs, and are prone to damage from vibrations.
Innovation Solution
A plug connector system with a guide-based design that includes a holding element and insulating element on a rail, featuring a spacer element for cable protection and a seal for pressure-tight and oil-tight connections, allowing for easy assembly and vibration resistance without the need for oil-tight cables or feedthroughs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oil-tight cables and screw connections are used to connect fuel injectors, then the connection is oil-tight and secure, but the mounting effort and costs increase significantly
Solution Approach 1:
The system divides the connection task into two separate components: a plug connector for electrical connection and a cable guide for mechanical guidance. This segmentation allows each component to be optimized independently, with the plug connector providing secure electrical contact and the cable guide ensuring proper cable routing without requiring complex screw connections.
Solution Approach 2:
The cable guide acts as an intermediary element between the cable and the plug connector. It provides mechanical support and positioning for the cable, eliminating the need for screw connections to secure the cable while ensuring proper alignment and connection security.
2Reliability
If oil-tight cables are used to connect fuel injectors, then the connection is oil-tight, but the costs increase significantly compared to non-oil-tight cables
Solution Approach 1:
The invention extracts the oil-tight sealing function from the cable itself and relocates it to the plug connector and cable guide assembly. This allows the use of simpler, non-oil-tight cables while maintaining the oil-tight connection through the dedicated sealing components in the connector system.
Solution Approach 2:
The system replaces expensive oil-tight cables with cheaper non-oil-tight cables combined with a reusable plug connector system. The sealing function is provided by replaceable seals in the connector rather than requiring the entire cable to be oil-tight, significantly reducing material costs.
3Reliability
If screw connections are used to mount cables on injector contacts, then the connection is secure against vibration, but the mounting effort increases
Solution Approach 1:
The invention merges the cable guidance function and the connection securing function into the integrated cable guide and plug connector assembly. This eliminates the need for separate screw connections to secure cables to injector contacts, as the cable guide provides both mechanical support and vibration resistance through its integrated design.
Solution Approach 2:
The cable guide and plug connector system is designed to self-align and self-secure during assembly. The cable guide automatically positions the cable correctly, and the plug connector provides inherent vibration resistance through its design, eliminating the need for additional fastening operations.
4Reliability
If individual cable mounting on injector contacts is performed, then the connection is secure, but the assembly complexity increases
Solution Approach 1:
The plug connector and cable guide assembly serves multiple functions simultaneously: it provides electrical connection, mechanical cable support, vibration resistance, and guidance for cable routing. This multi-functionality eliminates the need for multiple separate components and assembly steps, reducing overall assembly complexity while maintaining connection security.
Data Source
AI summary
A plug connector for connecting to an electric connection of a fuel injector of an internal combustion engine can comprise a rail extending in a longitudinal direction and at least one insulating element arranged in a linearly movable manner in the longitudinal direction relative to the rail, wherein the at least one insulating element protrudes out of the rail in a transverse direction. In some embodiments, the at least one insulating element comprises means for electrically connecting to the electric connection of the fuel injector in an oil-tight and releasable manner on a side facing away from the rail in the transverse direction. In some embodiments, the rail comprises a guide extending in the longitudinal direction configured to guide the at least one insulating element relative to the rail in the longitudinal direction and hold the same in a formfitting manner in the transverse direction relative to the rail.