Two-Step Plug-In Connector With Ramp Force Control
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Solution Overview
Problem
Existing electrical plug-in connection systems require additional movement between housings for reliable and cost-effective operation, which complicates the process and increases the risk of improper contact.
Innovation Solution
A two-step operating mechanism is introduced, where the relative movement of housings first locks them without initial contact, and then establishes contact with a position-dependent increase in force between contact elements, utilizing a ramp and elastic pressure part to ensure reliable and variable contact force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-step connection mechanism is used, then the structure is simpler, but the reliability of electrical contacting is reduced
Solution Approach 1:
The connection mechanism is divided into two distinct steps: a first locking step that secures the housings together, and a second contacting step that establishes electrical contact. This segmentation allows each step to be optimized independently, ensuring reliable electrical contacting while maintaining a manageable structural complexity through functional separation.
2Reliability
If contact force is applied immediately upon housing engagement, then the contacting is more reliable, but the locking mechanism cannot be properly established
Solution Approach 1:
The locking connection is established in a preliminary first step before the electrical contacting occurs in a second step. This preliminary locking action secures the housings together in proper alignment, making the subsequent electrical contacting reliable and easy to achieve without requiring precise manual alignment during the contacting phase.
3Reliability
If a two-step mechanism with position-dependent contact force is used, then the electrical contacting is more reliable, but the operating mechanism becomes more complex
Solution Approach 1:
The contact force is made dynamic and position-dependent rather than constant. As the housings move from the initial engagement position to the final locked position, the contact force between contact elements increases progressively. This dynamic force application ensures reliable electrical contacting while the complexity is managed through the natural mechanical progression of the two-step sequence.
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 solution allows for controlled and reliable electrical contacting with a position-dependent increase in contact force, ensuring operational reliability and cost-effectiveness by eliminating the need for additional movement between housings and optimizing the locking and contacting functions.
Implementation Method 1
a ramp may be constructed for this purpose in one of the housings by way of which a pressure part can be moved in the other housing. As a result of the interaction of the ramp and the pressure part, a position-dependent increase of the contact force can be caused in a particularly easy manner between the contact elements and their respective opposite contact elements.
Data Source
AI summary
An electrical plug-in connection system has a first electrical plug-in connection element and a second electric plug-in connection element complementary thereto. Pertaining first and a second housings having a number of contact elements corresponding to the number of the wires in the one housing and a corresponding number of opposite contact elements in the other housing are provided. An electrical plug-in connection between the contact elements and their respective opposite contact elements can be established and released again respectively by a relative movement of the two housings. A locking connection occurs between the two housings, which can be established and detached again. A two-step operating mechanism is provided, where, during the relative movement of the two housings in a first step, a locking of the two housings takes place essentially without providing contact between the contact elements and their respective opposite contact elements, and where, during the transition into an end position as the second step, the actual providing of contact between the contact elements and their respective opposite contact elements takes place with a position-dependent increase of the contact force.