Electrical Plug Connector With Integrated Sensor Carrier Assembly
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Solution Overview
Problem
Existing intelligent electrical connectors are complex and difficult to assemble due to the need for multiple components, including a conventional printed circuit board and additional circuit components, which complicates the assembly process and requires a separate cover for sealing.
Innovation Solution
The electrical connector features a one-piece carrier body made of a non-metallic material, such as plastic, with a non-plate shape and metallic conductor tracks, housing a sensor device and control device, which is easily inserted into the housing and secured with screw threads, simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional printed circuit board with separate sensor device and control device is used, then the electrical circuit functions are achieved, but the assembly process becomes complex and requires multiple components including a separate cover for sealing
Solution Approach 1:
The sensor device and control device are integrated onto a single printed circuit board, eliminating the need for separate carrier bodies and covers. This merging of components simplifies the overall structure and assembly process while maintaining all necessary electrical circuit functions
2Reliability
If multiple separate components (printed circuit board, sensor device, control device, cover) are used, then the electrical circuit with sensor and control functions is achieved, but the number of parts increases and assembly becomes more difficult
Solution Approach 1:
All electronic components including the sensor device and control device are mounted on a single printed circuit board, which is then directly inserted into the housing. This eliminates the need for multiple assembly steps and separate sealing covers, significantly improving ease of manufacture
Data Source
Figure 1~3
AI summary
The invention relates to an electrical plug connector (10) having contacts (30) on the input side and a housing (20), within which electrical lines (40) and an electrical switch with at least one sensor device (84) and a control device (82) are connected to the contacts (30). According to the invention, the sensor device (84) and the control device (82) are arranged on a common support body (70). The support body is designed as a circuit carrier, which is made from plastic by injection-molding, on which metallic conductor tracks (80) are applied. Advantages: Simple integration of sensor and monitoring tasks into conventional plug connectors.