Rotatable Disk Cam Connector for Compact High-Force Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-performance plug-in connector devices require large installation space for effective force amplification, which is a challenge in the automotive industry where space is limited and manufacturing costs are significant, while maintaining accessibility for maintenance and preventing unauthorized access.
Innovation Solution
A plug-in connector device utilizing a rotatable disk element with a cam mechanism that engages in a curved track, allowing for forceful connection over a long activation path, incorporating a gear mechanism for efficient force transmission and manufacturing cost reduction, and incorporating a unique tool access to prevent unauthorized access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If supplemental devices such as locking nuts with bayonet groove or activation lever are used to achieve high contact forces and large plug-in forces, then the connector achieves sufficient force amplification, but the installation space becomes excessively large due to large activation paths required
Solution Approach 1:
The disk element combines multiple functions: it serves as both the activation element and the force amplification mechanism through its cam track geometry. The crown wheel gear mechanism merges the activation motion with the force transmission, eliminating the need for separate locking nuts or activation levers with long paths. This integration achieves high plug-in forces within a compact space.
Solution Approach 2:
The cam track on the disk element uses curved geometry to transform rotational motion into linear plug-in motion with force amplification. The curved path of the cam track allows for a compact activation mechanism that achieves sufficient force multiplication without requiring long linear activation paths like traditional levers.
2Force
If traditional locking mechanisms with large activation paths are used, then sufficient force amplification is achieved, but the device complexity increases due to multiple supplemental components
Solution Approach 1:
The disk element integrates the activation mechanism and force amplification into a single component, eliminating the need for separate locking nuts, bayonet grooves, or activation levers. The crown wheel gear mechanism further integrates the motion transmission and force multiplication functions, significantly reducing the total number of components while maintaining high contact forces.
Solution Approach 2:
The disk element serves multiple functions simultaneously: it acts as the activation element, provides force amplification through its cam track, and engages with the crown wheel gear mechanism for motion transmission. This multi-functionality reduces device complexity by eliminating the need for multiple specialized components.
3Area of stationary object
If the connector is designed for compact installation space, then space constraints are satisfied, but access for maintenance purposes becomes difficult
Solution Approach 1:
The connector is divided into two separate plug-in units that can be easily connected and disconnected. The first plug-in unit contains the disk element while the second contains the crown wheel mechanism. This segmentation allows for compact installation while enabling easy maintenance access by simply separating the two units without requiring complex disassembly procedures.
4Ease of manufacture
If standard tool access is provided for the drive pinion, then manufacturing is simplified, but unauthorized access and intrusion cannot be prevented
Solution Approach 1:
The drive pinion uses a non-standard, asymmetric tool access geometry that does not match common standard tools. This asymmetric design prevents unauthorized access by requiring a specifically designed tool, while still allowing authorized maintenance personnel to access the connector with the appropriate specialized tool, thus balancing security with manufacturability.
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 a compact, cost-effective, and secure high-power density connector design that maintains accessibility for maintenance while preventing unauthorized access, achieving efficient force amplification and space-saving installation.
Implementation Method 1
a cam on the other plug-in unit engages in the curved track of the disk element. In this way, by simply rotating the disk elements, the two plug-in units may be fitted together, i.e., pulled together, forcefully over a relatively long activation path during the plug-in process
Implementation Method 2
the disk elements are not only carriers of the curved track but at the same time also form parts of a gear mechanism which transmits the input drive motion. The disk elements, i.e., the gear wheels, can be advantageously manufactured of plastic using injection molding processes
Implementation Method 3
the cams are guided so that they can be deflected in an elastically resilient manner and can be axially pre-stressed in the relevant curved track
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A plug-in connector device (10) for systems of high power density is provided with a first (female) plug-in unit (11), a second (male) plug-in unit (12), and a locking device (45) for the joining together, i.e., pulling together, and the force- or form-fitting holding of the first and second plug-in units (11; 12), which engage in and over each other when plugged into each other. To achieve an optimal construction size and good access for maintenance purposes, the locking device (45) is formed by at least one disk element (64, 65), which is supported on the first or second plug-in unit (11; 12) so that it can be rotatably driven, and by at least one cam (28) on the second or first plug-in unit (12; 11), said cam engaging in a curved track (67) of the disk element (64, 65) in a motion-locking manner.