Rotatable Wire Connector for Damper Piston Assembly
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Solution Overview
Problem
Conventional damping force variable dampers face issues with wire connectors that interfere with damper mounting operations and are prone to damage from external shocks, requiring quick and easy connection/disconnection in a narrow space with flexible orientation.
Innovation Solution
A wire connector system for a damper piston assembly featuring a rotatable socket part with guide protrusions and a plug part that includes a locking claw and rotation prevention protrusions, allowing easy connection and orientation adjustment at the end of the piston rod.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the wire and connector extend over a long distance from the piston rod, then the wire can reach the controller outside the damper, but the wire causes interference with damper mounting operations and is prone to damage from external shocks
Solution Approach 1:
The connector is divided into two separate parts: a socket part that connects to the piston rod and a plug part that connects to external wires. This segmentation allows the electrical connection to be made at the piston rod end, eliminating the need for long wire extensions that interfere with mounting operations.
Solution Approach 2:
The connector enables electrical connection in a different spatial dimension by providing a connection interface at the piston rod end rather than requiring wires to extend outward. This dimensional change in connection location eliminates the interference problem while maintaining electrical connectivity.
2Reliability
If the wire extends outward from the piston rod, then electric current can be supplied to the electric device inside the damper, but the exposed wire portion is vulnerable to damage from external shocks and disconnection
Solution Approach 1:
By segmenting the connector into socket and plug parts, the electrical connection is moved to the protected interior of the piston rod where it is shielded from external shocks. The socket part with locking protrusions provides a secure connection that resists disconnection from vibration and shock.
Solution Approach 2:
The locking protrusions and grooves are designed beforehand to prevent disconnection before external shocks can cause damage. The airtight seal and mechanical locking provide preemptive protection against environmental factors and vibration that could otherwise damage the wire connection.
3Productivity
If the connector is to be quickly connected and disconnected in a narrow mounting space, then the connection operation must be simple, but the connector must also maintain secure electrical connection
Solution Approach 1:
The separated socket and plug parts allow for quick connection and disconnection operations. The simple insertion and locking mechanism enables rapid assembly in narrow spaces while the locking protrusions ensure the connection remains secure during operation.
Solution Approach 2:
The connector design allows the socket and plug parts to self-align and self-lock through their geometric features (locking protrusions and grooves). This self-service mechanism eliminates the need for complex alignment procedures or additional fastening steps, enabling quick connection while maintaining reliability.
4Adaptability or versatility
If the wire extending outward from the piston rod must be freely orientable, then the connector must allow rotation and positioning, but the connection must remain secure against rotation during operation
Solution Approach 1:
The connector allows dynamic adjustment during installation through the rotatable socket part, enabling operators to position wires in the desired orientation. Once positioned, the locking mechanism transitions to a static state that prevents rotation during operation, providing both flexibility and stability.
Solution Approach 2:
The rotatable socket part allows preliminary orientation adjustment before final locking. Operators can rotate the socket to the desired position, then the locking protrusions engage to fix the position, combining flexibility during installation with stability during operation.
Data Source
AI summary
A piston assembly for a damper includes: a piston head; a piston rod having one end connected to the piston head, forming an inner space therein, and having another end at which an opening communicating with the inner space is formed; a wire having one end connected to an electric device mounted on the piston head and extending through the inner space of the piston rod; and a connector disposed at the other end of the piston rod and connected to another end of the wire. The connector includes a socket part rotatably disposed in the opening at the other end of the piston rod, and a plug part inserted into the socket through the opening of the other end of the piston rod. A self-alignment structure is provided in the socket part and the plug part and is configured to rotate the socket part such that the socket part is aligned at a predetermined orientation with respect to the plug part when the plug part is inserted into the socket part.