Plug Connector Lever Mechanism for Vibration-Resistant Locking
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Solution Overview
Problem
In motor vehicle technology, especially for electromobility, there is a challenge in securing electrical plug connections due to vibrational stressing, which can lead to faulty connections and vehicle failures if not properly secured.
Innovation Solution
A plug connector design featuring a pivotably mounted lever with an eccentrically positioned securing cam that is forcibly guided behind a locking surface via a ramp surface, ensuring a secure and error-free connection, utilizing a toggle lever mechanism and a spring element to maintain the initial position until the cam is locked, preventing unintended disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a securing device with a securing cam and locking surface is used to prevent unintended disconnection, then connection reliability is improved, but the risk of maloperation during assembly increases if the cam is not properly positioned
Solution Approach 1:
The ramp surface is pre-configured in the receptacle to automatically guide the securing cam into the correct position behind the locking surface during the plugging process. This preliminary geometric constraint ensures that the cam is properly positioned before the locking action occurs, preventing maloperation while maintaining connection reliability.
Solution Approach 2:
The ramp surface acts as an intermediary element between the securing cam and the locking surface. It mediates the interaction by gradually guiding the cam into the correct position, transforming the plugging motion into the precise cam positioning required for reliable locking without requiring manual intervention.
2Manufacturing precision
If the securing cam is forcibly guided behind the locking surface using a ramp surface, then error-free connection is guaranteed, but the complexity of the receptacle structure increases
Solution Approach 1:
The receptacle structure is segmented into distinct functional surfaces: the ramp surface for guiding, the locking surface for securing, and the insertion opening for access. This segmentation allows each surface to perform its specific function independently, achieving precise cam positioning while keeping the overall structure manageable and manufacturable.
Solution Approach 2:
The ramp surface utilizes a curved or inclined geometry to gradually guide the securing cam into the correct position. This curved path simplifies the guiding action compared to complex mechanical guides, as the cam naturally follows the ramp's geometry during insertion, reducing the need for additional positioning mechanisms.
3Reliability
If a spring element is used to hold the connecting element in its initial position, then protection against maloperation is improved, but the device complexity increases
Solution Approach 1:
The spring element provides self-service by automatically maintaining the connecting element in its initial position without requiring external control systems or additional actuators. The spring's elastic force continuously acts to return the element to its safe initial state, providing passive protection against maloperation while adding minimal complexity to the overall mechanism.
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
This design guarantees a reliable and secure plug connection by ensuring the securing cam is forcibly guided behind the locking surface during assembly, reducing the risk of maloperation and ensuring a form-fitting connection, thereby enhancing the durability and safety of electrical connections in motor vehicles.
Implementation Method 1
the connecting element is held in said initial position under pretension of a spring
Data Source
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AI summary
The present invention relates to a plug connector with a first plug (2) and a second plug (22), which have plug elements (6, 48) which are allocated to each other and can be connected to each other via plug contacting, and a securing device for mechanically securing the plugged-together plugs. In order to create a plug connector which, as far as possible, precludes assembly failures, in the present invention, the securing device is formed with a lever (30) which is pivotably mounted on the first plug (2) and which, eccentrically to its pivot axis, pivotably bears a connecting element (34) which has a securing cam (54) on its free end, the second plug (22) having a receptacle (46) which is formed adapted to form-fittingly receive the securing cam (54) and which has a ramp surface (62) which cooperates with the free end of the connecting element (34), via which ramp surface (62) the securing cam (54) is forcibly guided behind a locking surface (64) of the receptacle (46) during the plugging-together. In the inventive method of producing a plug connection between a first plug (2) and a second plug (22), during the plugging-together, a securing cam (54) which is provided on the free end of a connecting element (34) is forcibly guided behind a locking surface (64) which is formed at the second plug (22), and, subsequently, the two plugs (2, 22) are drawn towards each other by pivoting a lever (30) which pivotably bears the connecting element (34).