Portable Power Connector with RFID Tracking and Tapered Insulator
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Solution Overview
Problem
Existing portable power connectors are difficult to assemble, prone to poor connections due to large current-carrying loads, and lack consistency in size and material, leading to issues with making secure electrical connections, especially in harsh environments.
Innovation Solution
The development of a portable power connector system with a tapered insulator design and double set screw contacts, combined with an RFID transponder for identification and tracking, facilitates easier assembly and ensures secure connections while allowing for the management of life cycle information such as maintenance and warranty.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard electrical connectors are used for high-amperage power distribution, then power can be distributed to remote locations, but the connectors are difficult to assemble and prone to poor connections
Solution Approach 1:
The connector is divided into modular components including a cable assembly with pre-attached connector housing, contact elements, and sealing components. This segmentation allows each component to be manufactured and tested independently, then assembled together, reducing overall assembly difficulty while maintaining connection reliability through standardized interfaces.
Solution Approach 2:
Critical assembly steps are performed in advance during manufacturing, such as pre-installing contacts within the connector housing, pre-attaching sealing elements, and pre-configuring the cable assembly. This preliminary action ensures proper alignment and reduces the complexity of field assembly, allowing installers to simply connect pre-assembled units.
2Adaptability or versatility
If connectors are assembled in the field with multiple components, then customization is possible, but alignment and positioning are difficult leading to failed connectors
Solution Approach 1:
The connector design incorporates asymmetric features such as keyed interfaces, non-circular contact patterns, and positioned mounting holes that prevent incorrect orientation. This asymmetry ensures that components can only be assembled in the correct alignment, eliminating positioning errors while still allowing for different connector configurations to meet various customization needs.
Solution Approach 2:
Specific regions of the connector are designed with enhanced precision features where needed, such as precision-machined contact surfaces, localized alignment pins, and targeted sealing surfaces. Other areas use more tolerant, cost-effective manufacturing methods, optimizing the balance between alignment precision and manufacturing complexity.
3Productivity
If conventional connector assembly methods are used, then installation can be performed, but water ingress cannot be prevented without additional materials that increase installation time and cost
Solution Approach 1:
The sealing function is merged directly into the connector housing and cable assembly structure through integrated features such as molded grommets, O-ring grooves, and interference-fit interfaces. This integration eliminates the need for separate sealing materials and steps, preventing water ingress while maintaining fast installation speed and reducing overall cost.
Solution Approach 2:
The connector design incorporates self-sealing features where the act of assembly itself creates the water-tight seal. For example, the insertion of the cable into the housing automatically compresses a grommet or creates an interference fit that seals the interface, eliminating the need for additional sealing actions by the installer.
4Adaptability or versatility
If connectors from multiple manufacturers are used, then supplier options increase, but consistency and secure electrical connection cannot be ensured
Solution Approach 1:
The connector design establishes a universal interface standard with standardized dimensions, contact patterns, and mechanical coupling features that can be manufactured by multiple suppliers. This universality allows different manufacturers to produce interchangeable connectors that maintain consistent electrical and mechanical performance, enabling supplier competition while ensuring connection reliability.
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
The system provides a reliable and efficient method for assembling and securing power connectors, reducing the risk of poor connections and water ingress, while enabling effective tracking and management of electrical assets in rugged environments.
Implementation Method 1
an RFID transponder disposed within the connector, the transponder configured to transmit a first signal to a transmitting and receiving device and receive a second signal from the transmitting and receiving device
Data Source
AI summary
An electrical connector includes a female and male connector each having a tapered insulator and a contact with a first set screw a radial aperture. A set screw is received within the radial apertures, the set screws having an outer surface and a bore extending at least partway therethrough. A retaining screw is received within the bores of the set screws and corresponding aperture in the female and male connector. An RFID transponder is disposed within the connector. The transponder is configured to transmit a first signal to a transmitting and receiving device and receive a second signal from the transmitting and receiving device.