Power Supply Circuit Connector Lever Mechanism Vibration Resistance
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Solution Overview
Problem
Existing power supply circuit connectors for hybrid and electric cars require a compact design that allows safe manual disconnection for maintenance while ensuring operational safety and preventing detachment due to vehicular vibrations.
Innovation Solution
A power supply circuit connector with a lever mechanism that connects and disconnects main circuit and sensor terminals, utilizing a guide groove and pin mechanism to ensure secure mating and detachment, and an elastic locking member for stable operation, allowing the connector to be compact and resistant to vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a lever mechanism is used to connect main circuit terminals and sensor terminals, then the connector can be compact in size, but the connector may detach due to vehicular vibrations
Solution Approach 1:
The connector employs a dynamic locking mechanism where the lever can rotate between locked and unlocked positions. The guide groove and pin system allows the lever to dynamically adjust its position while maintaining a secure locked state during normal operation, preventing detachment due to vibrations while keeping the connector compact.
Solution Approach 2:
The guide groove and pin mechanism provides beforehand cushioning by pre-positioning the lever in a locked state that resists vibrational forces. The geometric constraint of the guide groove ensures the lever remains securely engaged with the housing before any detachment force is applied, preventing accidental disconnection.
2Ease of operation
If the guide groove is designed with gradually smaller distance R from rotary shaft, then the lever can rotate smoothly to connect terminals, but the manufacturing precision requirements increase
Solution Approach 1:
The guide groove is designed with deliberately varied geometric parameters - the distance R from the rotary shaft changes along the groove length. This parameter variation creates different mechanical effects: initially smaller R provides mechanical advantage for overcoming friction, while later larger R allows smooth completion of rotation. The design balances operational smoothness with manufacturable tolerances.
3Reliability
If the lever connects both main circuit terminals and sensor terminals in sequence, then the power supply circuit can be safely controlled, but the device complexity increases
Solution Approach 1:
The connector merges the functions of main circuit terminal connection and sensor terminal connection into a single lever-operated mechanism. By combining these functions, the patent reduces the number of separate components and operations needed, thereby managing device complexity while maintaining reliable sequential control of both terminal types.
Solution Approach 2:
The lever mechanism serves multiple functions: it connects main circuit terminals, connects sensor terminals, and provides mechanical locking. This multi-functionality reduces the need for separate mechanisms for each function, managing overall device complexity while ensuring safe control of the power supply circuit through sequential terminal connection.
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 solution enables safe and efficient manual disconnection of the power supply circuit, maintains compact size, and prevents detachment during vehicle travel, ensuring reliable power supply and easy maintenance.
Implementation Method 1
a lower end part of the second switch terminal being elastically deformable around an upper end part of the second switch terminal on right and left sides
Data Source
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AI summary
A power supply circuit connector includes: a first housing including: a pair of main circuit terminals connected with each other via a first switch terminal, and a pair of mated state sensor terminals connected with each other, a second housing mated with or detached from first housing, second housing including: first switch terminal for connecting the pair of main circuit terminals by a lever rotated to a first certain position; the lever rotatably supported to second housing and including: a second switch terminal for making the following operation: with the pair of main circuit terminals kept connected with each other, connecting the pair of mated state sensor terminals with each other by lever rotated to a second certain position after first certain position; and a mating-detaching mechanism for making the following operations by rotated lever mating second housing with the first housing, and detaching second housing from the first housing.