Power Connector Double-Blocking Structure Against Accidental Disconnection
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Solution Overview
Problem
Existing power connectors for machines, particularly those used in hot melt adhesive machines, suffer from accidental disconnection due to fragile lever elements and require excessive force for secure closure, leading to issues like adhesive cooling and solidification.
Innovation Solution
A connector design featuring a male element with protruding pins and a protective piece with tubular structure, including blocking and anchoring devices, ensures secure connection through wedged fitting and axial retention, preventing accidental disconnection and facilitating assembly/disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lever elements with chamferings are used for blocking, then connector closure is secured, but pins become more fragile and break easily
Solution Approach 1:
The blocking function is divided between two separate pins instead of relying on a single pin with chamferings. Each pin has its own blocking mechanism, distributing the mechanical stress and reducing the risk of complete failure. The first pin engages with a blocking element while the second pin provides additional blocking support, creating a segmented blocking system that is more reliable and less fragile.
Solution Approach 2:
A blocking element acts as an intermediary component between the two pins and the connector body. This blocking element receives the blocking force from both pins and transfers it to the connector body, preventing direct stress concentration on the pins themselves. The blocking element serves as a mediator that protects the pins from breaking while still achieving secure closure.
2Reliability
If pins are made stiff with chamferings, then blocking is improved, but larger force is required for opening and engagement
Solution Approach 1:
The blocking force is segmented and distributed across two pins rather than concentrated on a single stiff pin. This segmentation allows each pin to engage more gradually with its corresponding blocking element, reducing the peak force required during engagement and opening operations while maintaining reliable blocking performance.
Solution Approach 2:
The blocking system incorporates dynamic elements that allow for gradual engagement. The blocking element can move axially and rotate, enabling a progressive engagement process where force is applied incrementally rather than all at once. This dynamic behavior reduces the sudden force spikes that would otherwise be required to engage stiff, chamfered pins.
3Device complexity
If a single blocking element is used, then device complexity is reduced, but connection reliability is insufficient
Solution Approach 1:
The blocking function is segmented into two separate pins working in parallel, each providing independent blocking support. This segmentation increases reliability because the failure of one pin does not compromise the entire blocking system. The dual-pin configuration creates redundancy that ensures secure connection even if one pin experiences wear or damage.
Solution Approach 2:
The two pins are combined with a single blocking element that interacts with both pins simultaneously. This merging approach allows the blocking element to coordinate the blocking action of both pins, providing enhanced closure assurance. The blocking element integrates the blocking forces from both pins into a unified blocking mechanism, achieving high reliability without requiring two completely separate blocking systems.
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a connector for supplying electric power to a machine or other devices that require electrical energy, the connector facilitating and securing the connection, thereby preventing possible accidental disconnection. The connector comprises a male connector element (1), a protective piece (3), and a blocking device that, in a closed position of the connector, provides double blocking on a single element forming part of the male connector element (1), to prevent the connector of the invention from disconnecting. The blocking device is configured to block pins (5) from tilting in the closed position of the connector, wherein the blocking device comprises rear projections (11) solidly connected to the protective piece (3), and end portions solidly connected to the pins (5).