Self-Aligning Plug-In Module for Misaligned Wall Box Connectors
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Solution Overview
Problem
In modern prefab housing, where cables and wall boxes are casted in concrete, misalignment of wall boxes during casting leads to installation challenges for plug-and-play utility control modules, particularly for optical connections, and conventional fixtures require manual wiring, making them difficult for inexperienced users.
Innovation Solution
A plug-in module with a self-aligning and self-connecting coupling mechanism that allows for easy installation by aligning and connecting to cable end connectors within a wall box, even with misalignments, and a method for connecting to both optical and electrical conductors without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plug-and-play utility control module is used for easy installation, then ease of operation is improved, but manufacturing precision of wall box positioning is worsened due to casting misalignment
Solution Approach 1:
The coupling mechanism incorporates adjustable parameters including rotational freedom and lateral shifting capability, allowing the plug-in module to adapt to misaligned wall boxes while maintaining secure optical and electrical connections
Solution Approach 2:
The coupling mechanism is designed with dynamic adjustment capabilities during the plugging process, enabling real-time alignment correction through rotation and lateral movement to compensate for casting misalignments
2Reliability
If the plug-in module is fully inserted and precisely aligned for proper electrical connections, then connection reliability is improved, but ease of operation is worsened due to inability to adjust for misalignment
Solution Approach 1:
The coupling mechanism provides dynamic adjustment during insertion through rotational freedom and lateral shifting, enabling the module to achieve precise alignment and reliable connections even when the wall box is misaligned
Solution Approach 2:
The coupling mechanism performs self-alignment through its inherent rotational and lateral adjustment capabilities, automatically compensating for misalignment without requiring manual intervention or precise initial positioning
3Adaptability or versatility
If conventional fixtures with manual connection are used for flexibility in adjustment, then adaptability is improved, but device complexity is worsened due to manual wiring requirements
Solution Approach 1:
The coupling mechanism automatically performs alignment and connection functions through its rotational and lateral adjustment capabilities, eliminating the need for manual wiring operations while maintaining adaptability to misaligned installations
Solution Approach 2:
The coupling mechanism integrates multiple functions including alignment adjustment, optical connection, and electrical connection into a single automated component, reducing overall system complexity while maintaining flexibility
Data Source
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AI summary
The invention relates to a plug-in module for connecting to a first end connector of a first cable within a wall box, wherein the plug-in module comprises a front side for receiving a front panel, a rear side opposite to the front side and a plug-in body extending in a plug-in direction from the front side towards the rear side for plugging into the wall box in said plug-in direction, wherein the plug-in module further comprises a coupling mechanism that is arranged for self-aligning with the first end connector and for self-connecting to the first end connector in a connection direction transverse to the plug-in direction in response to plugging the plug-in body into the wall box in the plug-in direction. The invention further relates to a set of the aforementioned plug-in module and a wall box and to a method using the set to establish the abovementioned connection.