Self-aligning Connector Gravity-Assisted Drone Installation
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Solution Overview
Problem
The existing methods for installing or replacing electronic devices on outdoor light fixtures require manual intervention, often necessitating the use of bucket trucks, which are costly and inefficient, and pose challenges for drones due to high torque and pressure issues, as well as precision alignment requirements.
Innovation Solution
A self-aligning connector assembly featuring a base with a first alignment feature and a self-alignment component with a second alignment feature, where the self-alignment component rotates under gravity to form an electrical connection, facilitated by a flying drone for easy installation and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual installation methods are used with bucket trucks, then installation can be performed, but installation costs and time consumption increase significantly
Solution Approach 1:
The connector performs self-alignment through its asymmetric geometry. The flat surface of the connector automatically aligns with the corresponding flat surface of the receptacle during insertion, eliminating the need for manual alignment adjustments by workers in bucket trucks.
Solution Approach 2:
Instead of requiring manual twisting and locking operations, the design inverts the approach by using gravity-assisted insertion where the connector naturally orients itself during downward motion, with the asymmetric features guiding alignment automatically.
2Productivity
If drones are used for installation, then installation costs decrease, but precision alignment becomes difficult due to high torque and pressure issues
Solution Approach 1:
The connector features an asymmetric design with a flat surface on one side and rounded edges on the other. This asymmetry creates a unique orientation that guides the connector into proper alignment with the receptacle during drone-delivered insertion, eliminating the need for precision manual alignment.
Solution Approach 2:
The asymmetric geometry enables self-alignment during the insertion process. As the drone releases the connector, gravity causes it to rotate and settle into the correct orientation automatically, with the flat surfaces mating precisely without requiring manual intervention for alignment.
3Reliability
If traditional twist/lock mechanisms are used, then electrical connection is established, but the operation requires high torque that drones cannot provide
Solution Approach 1:
Instead of requiring the drone to twist and lock the connector (which would require high torque), the design inverts the mechanism: the connector is simply inserted and allowed to settle under gravity, with the asymmetric features automatically engaging the locking positions without requiring rotational force.
Solution Approach 2:
The connector's asymmetric geometry causes it to self-align and self-lock during insertion. The flat surfaces mate automatically, and the rounded edges guide the connector into its final positioned state without requiring external torque application.
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
This solution significantly reduces installation and replacement costs, increases the rate of electronic component updates, and enhances lighting performance by allowing drones to efficiently replace devices on outdoor lighting fixtures without the need for bucket trucks, thereby improving operational efficiency and reducing maintenance costs.
Implementation Method 1
The flying drone then releases the alignment component such that the second alignment feature contacts or mates with the first alignment feature, which causes rotation of the alignment component under the force of gravity in a downward direction.
Data Source
AI summary
A self-aligning connector assembly for a light fixture. In some embodiments, the self-aligning connector assembly includes a base and a self-alignment component. The base includes a first alignment feature extending from a platform and a first electrical contact, and the self-alignment component includes a second alignment feature and a second electrical contact. When the self-alignment component is positioned over and then released onto the base, the first alignment feature mates with the second alignment feature which causes rotation of the self-alignment component under the force of gravity, resulting in operably connecting the first electrical contact to the second electrical contact.