Rotatable High-Voltage Connector Locking for Easier Alignment
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Solution Overview
Problem
In high voltage connections, particularly in automotive environments, operators face difficulties aligning and polarizing plug connectors with header assemblies due to rigidity, and existing solutions require separate parts for strain relief and connector position assurance, increasing complexity and part count.
Innovation Solution
A high voltage connector design featuring a rotatable inner terminal portion with an inner carrier element between the terminal and outer housing, a locking assembly for alignment, and a multi-function retainer element providing locking, connector position assurance, and strain relief, reducing the number of required parts and facilitating assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a direct locking mechanism is used for high voltage connector assembly, then connection stability is improved, but alignment difficulty increases due to rigidity
Solution Approach 1:
The connector employs a two-stage locking mechanism that transitions from a dynamic pre-lock state allowing rotation to a static final lock state preventing rotation. The inner terminal portion can rotate during assembly (dynamic) to facilitate alignment, then locks in place (static) to ensure connection stability.
Solution Approach 2:
The locking mechanism is divided into separate functional stages: a pre-lock condition that permits rotational movement for alignment, and a final lock condition that prevents rotation for stable connection. This segmentation allows each stage to optimize for its specific function.
2Reliability
If separate parts are used for strain relief and connector position assurance, then functional reliability is improved, but device complexity increases
Solution Approach 1:
The connector integrates multiple functions into unified components. The locking assembly combines strain relief features with connector position assurance capabilities, eliminating the need for separate dedicated parts for each function while maintaining all required safety and performance features.
Solution Approach 2:
The locking assembly is designed as a multi-functional component that simultaneously provides strain relief, connector position assurance, and mechanical locking. This universal component performs multiple critical functions that would traditionally require separate specialized parts.
Data Source
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AI summary
A high voltage connector is provided which comprises an inner terminal portion, an outer housing, and an inner carrier element disposed between the inner terminal portion and the outer housing such that the inner terminal portion is rotatable with respect to the outer housing. The high voltage connector further comprises a locking assembly which allows for a rotation of the inner terminal portion in a pre-lock condition of the high voltage connector and which prevents the rotation of the inner terminal portion in a final lock condition of the high voltage connector. A method for providing a high voltage connection is also provided.