Electrical Plug-In Connection With Tooth System for Vibration Resistance
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Solution Overview
Problem
Existing electrical plug-in connections in the motor vehicle industry face challenges in achieving high vibration resistance, particularly in high-voltage applications, where they must withstand mechanical and electromagnetic interference while ensuring secure and reliable transmission of electrical energy and signals in harsh environments.
Innovation Solution
The design incorporates a tooth system in the plug-in connector and a mating tooth system in the mating connector, which engage elastically or interlock when an operating element moves from a home position to a locking position, providing enhanced vibration resistance through axial engagement and radial force absorption, and includes a multi-part plug-in connector body with shielding and fastening means for secure housing integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical plug-in connections are used in high-voltage applications, then electrical energy transmission is enabled, but vibration resistance is insufficient and unintended disconnection may occur
Solution Approach 1:
The connector is divided into two separate components: a plug-in connector and a mating plug-in connector. This segmentation allows each component to have optimized features for its specific function, with the tooth system on one side and mating tooth system on the other, improving overall vibration resistance while maintaining manageable complexity
Solution Approach 2:
The connector assembly combines different material properties and structural features - the tooth system and mating tooth system create a composite mechanical engagement that provides enhanced vibration resistance beyond what a single conventional connector design could achieve
2Reliability
If the connector structure is simplified for ease of manufacture, then manufacturing cost decreases, but vibration resistance and connection security deteriorate
Solution Approach 1:
The tooth system and mating tooth system are pre-configured on the respective connectors before assembly. When the connectors are mated, the operating element automatically moves from home position to locking position, engaging the tooth systems in advance to provide immediate vibration resistance without requiring additional assembly steps
Solution Approach 2:
The connector design enables self-locking through the interaction between the operating element and guide means. When the plug-in connector is inserted, the operating element automatically transitions to the locking position, engaging the tooth systems without requiring external intervention, thereby maintaining connection security while simplifying the assembly process
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 configuration significantly enhances the vibration resistance and reliability of electrical plug-in connections, enabling secure transmission of high-voltage electrical signals and power in motor vehicles, even in contaminated and chemically aggressive environments, while preventing unintended disconnection.
Implementation Method 1
the tooth system (8) and the mating tooth system (9), when they are in engagement with one another, are in engagement in a force-fitting manner, preferably are pressed together elastically one into the other
Data Source
AI summary
The invention relates to an electrical plug-in connection, comprising an electrical connector and a mating electrical connector, which can be connected to the electrical connector. The mating electrical connector has an actuating element, which can be moved between a home position (P0) and a locking position (P1) and is designed to cooperate with a guiding element of the electrical connector in such a way that the plug-in connection, proceeding from a pre-latching position, assumes a locked position when the actuation element is moved from the home position (P0) into the locking position (P1). The electrical connector has a toothing and the mating electrical connector has a mating toothing, which corresponds to the toothing of the electrical connector, the toothing and the mating toothing mesh with one another in the locked position of the plug-in connection.