Multi-Diameter Power Pin Socket for One-Handed Torch Connection
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Solution Overview
Problem
Conventional electrical connectors for arc process systems, such as welding or plasma cutting, require two-handed operation for secure connection, leading to potential instability, fluid leakage, and inefficient power transfer due to misalignment or obstruction issues, and the liner installation process is cumbersome and prone to damage.
Innovation Solution
A multi-diameter power pin with a proximal, engagement, bearing, and threaded distal portion, combined with a receiving block featuring a multi-diameter through hole and radial gaps, allows for one-handed secure connection and easy liner installation without tools, ensuring efficient electrical and fluid transfer by providing a dedicated engagement mechanism and unobstructed contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional single-diameter power pin is used, then the connector structure is simple, but the user cannot securely connect with one hand and may cause misalignment or obstruction issues
Solution Approach 1:
The power pin is segmented into multiple portions with different diameters: a proximal portion, an engagement portion with smaller diameter, a bearing portion with intermediate diameter, and a threaded distal portion with smallest diameter. This segmentation allows each portion to serve a specific function while enabling one-handed operation through the engagement portion's reduced diameter that fits into a corresponding recess in the socket.
Solution Approach 2:
Different portions of the power pin have different local qualities (diameters) optimized for specific functions. The engagement portion has a smaller diameter localized at that region to enable finger access and one-handed connection, while other portions maintain larger diameters for structural support and electrical contact.
2Reliability
If a bolt is used to secure the liner, then the liner can be held in place, but over-tightening may damage the liner and cause weld wire to kink
Solution Approach 1:
The connector is designed to be self-servicing through the multi-diameter engagement mechanism that automatically aligns and secures the plug into the socket without requiring external tools or manual tightening operations that could damage components.
Solution Approach 2:
The bolt mechanism for securing the liner is eliminated entirely. Instead, the liner is retained through the engagement portion and bearing portion design that provides inherent mechanical retention without requiring separate fastening elements that could be over-tightened.
3Reliability
If the user must hold the plug with one hand and clamp with the other, then secure connection can be achieved, but the user becomes unstable on the robot and risks falling
Solution Approach 1:
The connection mechanism is segmented into distinct functional portions that enable automatic alignment and engagement. The engagement portion with its smaller diameter fits into a corresponding recess, creating a self-aligning feature that allows secure connection through a single insertion motion without requiring the user to simultaneously hold and clamp.
Solution Approach 2:
The engagement portion is pre-configured with a diameter that matches the recess in the socket, creating a preliminary alignment feature that guides the plug into proper position during insertion. This preliminary action ensures correct alignment before final engagement, eliminating the need for manual positioning with both hands.
4Manufacturing precision
If conventional two-handed operation is required, then proper alignment can be achieved, but the connection process is time-consuming and reduces productivity
Solution Approach 1:
The engagement portion and bearing portion are pre-configured with specific diameter relationships that create automatic alignment during insertion. The engagement portion's smaller diameter fits into a recess that guides the plug into the correct angular and positional orientation, while the bearing portion maintains proper spacing and alignment as the connection is finalized.
Solution Approach 2:
The multi-diameter segmentation of the power pin creates distinct functional zones that perform alignment and engagement functions in sequence during a single insertion motion, eliminating the need for separate positioning and clamping operations.
Data Source
AI summary
An electrical connector is disclosed. The electrical connector includes a multi-diameter power pin having a proximal portion having a first diameter; an engagement portion having a second diameter smaller than the first diameter; a bearing portion having a third diameter smaller than the second diameter; and a threaded distal portion having a fourth diameter smaller than the third diameter. A receiving block having a multi-diameter through hole is configured to receive the multi-diameter power pin. The receiving block includes a plurality of gaps extending radially from the multi-diameter through hole to an outer surface of the receiving block, a receiving portion disposed between a lateral surface of the receiving block and a first gap of the plurality of gaps; and a clamping portion disposed between the plurality of gaps.