Self-Aligning Modular Electrical Connector for Robotic Tool Changers
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Solution Overview
Problem
Existing robotic tool changers face misalignment issues with electrical connections, leading to incomplete circuit connections and safety hazards due to exposed conductive plates.
Innovation Solution
A modular electrical connector assembly with self-aligning socket and pin assemblies, featuring a nonconductive guide bushing and compliant members, such as o-rings, to ensure secure and safe electrical connections between robotic tool changer modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring-loaded pins with guide pins and receiving holes are used for electrical connections, then electrical power and data signals can be passed between modules, but misalignment occurs in multiple axes resulting in incomplete circuit connections
Solution Approach 1:
The patent employs spring-loaded pins that can dynamically adjust their position through elastic deformation. The pins are mounted on springs that allow them to move axially and laterally, enabling automatic compensation for misalignment between connector blocks while maintaining reliable electrical contact.
Solution Approach 2:
The connector design utilizes compliant members with specific elastic properties that change under load. The spring constant and material properties are selected to optimize both alignment tolerance and contact force, allowing the system to adapt to varying alignment conditions while maintaining reliable connections.
2Reliability
If spring-loaded pins with exposed conductive plates are used, then electrical connections can be established, but shock hazards and short circuit hazards are created
Solution Approach 1:
The patent introduces non-conductive insulating materials between the exposed conductive plates and the external environment. These insulating barriers prevent direct contact with live electrical components, eliminating shock and short circuit hazards while allowing electrical connections to function normally through the insulated pin structure.
Solution Approach 2:
The design uses replaceable insulating covers or protective elements that can be easily replaced if damaged. These protective components are simpler and less expensive than redesigning the entire connector, providing a cost-effective solution to the safety hazard problem.
3Adaptability or versatility
If modular electrical connector assemblies are used to accommodate various utilities, then versatility is improved, but device complexity increases
Solution Approach 1:
The patent designs a universal connector block interface that can accommodate multiple types of utility modules (electrical, pneumatic, hydraulic, data) through a standardized mounting mechanism. The same basic connector block structure supports different utility types, reducing the need for specialized connectors for each utility type and thereby managing complexity.
Solution Approach 2:
The connector system is divided into independent, interchangeable modules. Each utility type is implemented as a separate module that can be attached to or removed from the connector block, allowing the system to be configured for specific applications without redesigning the entire connector assembly. This modular approach manages complexity by breaking down the system into manageable, standardized components.
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 provides reliable, self-aligning electrical connections with reduced contact resistance, enhanced safety by minimizing shock hazards, and ease of maintenance through field-replaceable components, accommodating various robotic applications with a reduced inventory of modular components.
Implementation Method 1
A compliant member such as an o-ring provides compliance of the socket and pin assemblies in the signal connector blocks, making the assemblies self-aligning
Data Source
AI summary
A modular approach to an electrical power and/or signal passing utility module is presented. A universal receptacle is fixedly disposed in bores in both of first and second signal connector blocks. A threaded socket member and a nonconductive guide bushing are installed, as needed, in receptacles in the first block, and a threaded pin member is installed in corresponding receptacles in the second block. The nonconductive guide bushing insulates the sockets, and guides pin posts into the socket as the two blocks abut. A compliant member such as an o-ring provides compliance of the socket and pin assemblies in the signal connector blocks, making the assemblies self-aligning. The socket and pin assemblies are field-replaceable by use of a simple tool.