Plug Secondary Locking Mechanism for Vehicle Wiring Harnesses
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Solution Overview
Problem
Miniaturized electrical plugs for vehicle wiring harnesses face challenges in maintaining a stable and durable connection due to the risk of locking element prongs breaking off, especially when the locking element is guided exclusively in the lower part of the contact carrier with a small cross-section.
Innovation Solution
The plug design incorporates a locking element that extends through both the upper and lower parts of the contact carrier with an enlarged cross-section, featuring prongs that engage with recesses in a form-fitting manner, ensuring robust fixation of electrical lines through stiction and preventing slippage under vibrations, and can be inserted transversely to accommodate multiple lines simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the locking element is guided exclusively in the lower part of the contact carrier with a small cross-section, then the plug achieves a miniaturized design, but the locking element prongs are prone to breaking off
Solution Approach 1:
The locking element is extended from the lower part of the contact carrier into the upper part, utilizing the vertical dimension to increase the cross-sectional area and structural strength without increasing the horizontal footprint of the plug. This allows the plug to maintain its miniaturized design while significantly improving the durability of the locking element prongs.
2Reliability
If the locking element extends through both upper and lower parts of the contact carrier, then the fixation force is distributed more effectively, but the device complexity increases
Solution Approach 1:
The locking element serves multiple functions simultaneously: it provides mechanical locking, distributes fixation force across both upper and lower contact carrier parts, and maintains structural integrity. This multi-functional design achieves improved fixation stability without proportionally increasing device complexity, as the same component performs multiple roles.
3Reliability
If the prongs are designed to engage with recesses in a form-fitting manner, then the electrical lines are securely fixed against vibrations, but the manufacturing precision requirements increase
Solution Approach 1:
The form-fitting engagement between prongs and recesses creates localized high-strength connection points at critical locations where electrical lines are most susceptible to vibration-induced displacement. This concentrated quality enhancement provides vibration resistance without requiring uniform high precision throughout the entire plug assembly.
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 enhances the stability and longevity of electrical connections by distributing the fixation force more effectively, reducing the likelihood of prong breakage and ensuring precise alignment of electrical lines, thereby increasing the reliability and service life of the connections.
Implementation Method 1
ensuring robust fixation of electrical lines through stiction and preventing slippage under vibrations
Data Source
AI summary
A plug for establishing an electrical connection to a plug module includes: a plug body having a contact carrier upper part which includes multiple first channels to accommodate electrical lines, and a plug base accommodating a collar of the plug module; a contact carrier lower part which includes multiple second channels to accommodate the electrical lines; and a locking element insertable into the plug from the outside and configured to fix the electrical lines in the channels. The first channels terminate in the second channels to form continuous channels accommodating the electrical lines. The contact carrier lower part is enclosed by the collar of the plug module and accommodates multiple electrical contacts of the plug module in order to establish electrical connections between the multiple electrical lines in the plug and the multiple electrical contacts of the plug module.