Plug Connector Assembly Rotary Lever Guide Path Mechanism
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Solution Overview
Problem
Existing plug connector assemblies with rotary levers face challenges in stabilizing high-force connections, particularly in high-load applications like electric vehicle charging, where the weight and leverage of high-current lines cause tilting of contact elements, and require complex mechanisms involving both rotational and linear movements for connection and disconnection.
Innovation Solution
A plug connector assembly design featuring a rotary lever with parallel side faces and a slide mechanism, where guide pins on the second plug connector housing are inserted into guide paths on the rotary lever, allowing for rotational movement that aligns the plug connector housings and includes driver elements for linear movement and locking, simplifying the connection process and stabilizing the contact elements through a form-fit locking action.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a rotary lever mechanism is used to connect plug connectors with high insertion forces, then the connection force is sufficient to connect multiple contact elements, but the mechanism becomes complicated requiring both rotational and linear movements
Solution Approach 1:
The connection mechanism is segmented into two independent parts: a rotary lever for generating high insertion force and a separate slide for providing linear guiding and locking. This segmentation allows each component to perform its specific function efficiently without adding unnecessary complexity to the overall system.
Solution Approach 2:
The slide acts as an intermediary element between the rotary lever and the plug connector housing. It translates the rotational motion into linear movement and provides the locking function, simplifying the overall mechanism by separating the force generation and motion conversion functions.
2Stability of the object's composition
If multiple pins are integrally formed on the plug connector housing to counteract forces from high-current lines, then the stability improves, but the device complexity increases
Solution Approach 1:
The slide with its driver element acts as a counterbalancing mechanism that compensates for the forces generated by heavy high-current lines. By providing a form-fit connection through the driver element and guide path, it stabilizes the contact elements without requiring multiple complex pins to be integrally formed on the housing.
3Force
If a rotary slide lever mechanism is used for connection, then high insertion forces are achieved, but the connection process requires two sequential movements (rotation and sliding)
Solution Approach 1:
The operation is segmented into two simple, independent actions: rotating the lever and automatic slide engagement. The slide is guided to move linearly by the rotary lever's motion, so the user only needs to perform the simple rotation while the slide automatically completes the linear connection and locking motion.
Solution Approach 2:
The slide mechanism is designed to automatically engage and lock itself during the rotation process. The driver element on the slide automatically interacts with the guide path on the rotary lever, causing the slide to move linearly and establish the locking connection without requiring additional manual intervention.
Data Source
AI summary
A plug connector assembly includes first and second connector housings, a rotary lever, and a slide. The rotary lever has side faces each having a guide path into which in each case a guide pin on the second connector housing is inserted and is displaced along the guide path by rotation of the rotary lever whereby the connector housings move toward one another and electrical contact elements thereof connect. The slide is movable on the second plug connector housing. A driver element of the rotary lever cooperates in a form-fit manner with a driver element of the slide when the rotary lever rotates causing the slide to linearly move. A locking element of the slide is displaced relative to a locking element of the first connector housing when the slide linearly moves whereby a form-fit locking action between the locking elements may be established or cancelled.