Rotatable High-Current Connector for Coded Cable Outlet Alignment
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Solution Overview
Problem
High-current connectors face challenges in flexible alignment and coding to prevent incorrect connections, especially in restricted installation spaces, where the direction of angled cable outlets is often predefined by coding, leading to space and operational inefficiencies.
Innovation Solution
A high-current connector system with a rotatable insulating body and a mating connector that can be aligned and coded through a polarization element and coding element, allowing the angled cable outlet to be oriented variably, while maintaining coding to prevent incorrect connections, by using a pin contact with a screw thread for secure attachment to a busbar and allowing the mating connector to be rotated independently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coding elements are used to prevent incorrect connections, then connection safety is improved, but the flexibility of cable outlet orientation is reduced
Solution Approach 1:
The connector is divided into separate functional elements: the housing with coding elements for safety, and the cable outlet assembly that can be independently oriented. This segmentation allows the coding function to remain fixed while the cable outlet orientation becomes flexible through the rotatable insulating body mechanism.
Solution Approach 2:
The insulating body is designed to be rotatable relative to the housing, transforming the previously static connector into a dynamic system. This allows the cable outlet orientation to be adjusted after the connector is assembled and coded, providing adaptability without compromising the fixed coding safety mechanism.
2Reliability
If the cable outlet direction is fixed by coding, then incorrect connections are prevented, but space requirements in installation areas increase
Solution Approach 1:
The rotatable insulating body enables the cable outlet to be oriented in different directions within a compact footprint. This dynamic orientation capability allows the connector to adapt to various installation space constraints without requiring additional installation area, while the coding elements maintain prevention of incorrect connections.
Solution Approach 2:
The orientation parameter of the cable outlet can be changed after assembly by rotating the insulating body. This parameter change capability allows the same connector to fit different spatial configurations without increasing the base installation area, while coding ensures safety.
3Manufacturing precision
If the connector assembly requires multiple components for coding and alignment, then connection precision is improved, but device complexity increases
Solution Approach 1:
The coding elements and alignment function are merged into the housing structure, while the rotatable insulating body combines both rotation capability and insulation functions. This merging reduces the number of separate components needed compared to using separate alignment features and coding mechanisms.
Solution Approach 2:
The insulating body serves multiple functions: electrical insulation, rotation mechanism for orientation adjustment, and carrier for the plug contact. The housing serves as both the structural base and the carrier for coding elements. This multi-functionality reduces overall device complexity while maintaining precise connection alignment through the integrated design.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
The aim of the invention is for a high-current electrical connector (1) to be codable for use with a certain mating electrical connector and to be flexibly and comfortably adaptable to the conditions of a tight installation space in which the high-current electrical connector is used. This aim is achieved in that the insulating body (14) of the high-current electrical connector is retained on the pin contact (11) such that said insulating body can be rotated about the pin axis (S). Thus, the mating electrical connector (4) connected thereto, coded therefor and aligned therewith can be rotatably retained such that the angled cable outlet (42) of the mating electrical connector can be flexibly oriented within the installation space as required.