Quick Replacement Connector Segmentation for Towing Maintenance
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Solution Overview
Problem
Conventional electrical connectors used for towing vehicles, such as SAE J560 connectors, degrade quickly due to repeated connection and disconnection, making maintenance costly and impractical, as they require replacing entire connectors rather than individual components.
Innovation Solution
A quick replacement connector system with a twisting lock mechanism and cable assembly featuring a handle and terminal holders, allowing for efficient disassembly and reassembly of replaceable components, facilitating maintenance without affecting the rest of the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors are used with soldered or sonically welded terminals, then reliable electrical connection is achieved, but replacement of degraded components becomes impractical and costly
Solution Approach 1:
The connector is divided into separate modular components: a housing, a terminal holder, and individual terminals. Each terminal can be independently removed from the terminal holder without affecting other terminals, allowing selective replacement of only degraded components while maintaining reliable electrical connections through the modular interface.
Solution Approach 2:
The terminal holder is extracted as a separate replaceable component from the housing. Terminals are designed to be removable from the terminal holder, enabling the extraction and replacement of individual degraded terminals without replacing the entire connector assembly, thus improving repair ease while maintaining connection reliability.
2Reliability
If entire connector is replaced for maintenance, then proper functioning is ensured, but maintenance becomes time-consuming and costly
Solution Approach 1:
The connector assembly is segmented into housing, terminal holder, and individual terminals. This segmentation enables maintenance personnel to access and replace only the specific degraded terminal or terminal holder rather than the entire connector, significantly reducing maintenance time while ensuring proper functioning through replacement with new components.
Solution Approach 2:
The design enables selective discarding of only the degraded terminal or terminal holder components while recovering and retaining the functional housing and other intact terminals. This selective replacement approach reduces maintenance time and costs compared to replacing the entire connector assembly.
3Reliability
If conventional connector design is used, then electrical connection is established, but repeated connection and disconnection causes rapid degradation
Solution Approach 1:
The connector is segmented into modular components that can be independently replaced. The terminal holder and terminals are designed as separate replaceable units from the housing, allowing degradation from repeated connection/disconnection to be localized to specific components rather than affecting the entire connector, thereby extending the overall service life of the connector assembly.
Solution Approach 2:
The modular design allows the functional housing to be recovered and retained while only the degraded terminal holder or terminals are discarded and replaced. This extends the service life of the connector assembly by separating the durable housing from the wear-prone terminal components.
Data Source
AI summary
Implementations described and claimed herein provide apparatuses, systems, and methods for a quick maintenance of an electrical connector, such as a SAE J560 compliant connector. In one implementation, a connector includes a cable bundling wires extending into a housing having a body extending between a proximal end and a distal end. A distal terminal holder is disposed within an opening of the body at the proximal end. The distal terminal holder has a surface oriented in a direction away from the body. Terminals extend from the surface of the distal terminal holder, and each of the terminals is in electrical communication with one of the wires. Terminal assemblies each have a distal opening into which one of the terminals extends. A proximal terminal holder has terminal openings extending from a distal surface to a proximal surface, and each of the terminal assemblies extends through one of the terminal openings.