Snap-Locking Electrical Connector Assembly for Aircraft Vibration
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Solution Overview
Problem
Existing electrical connectors for aircraft are labor-intensive, require complex installation, are not robust enough to withstand vibration, and often need complete replacement upon damage, while also being large and inefficient in space usage.
Innovation Solution
A pin and socket assembly with a locking mechanism using a rotatable locking collar and flexible fingers that engage and lock together, allowing easy mating and locking without specialized tools, and enabling quick disconnection and reconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connectors are used in aircraft, then robust connection is achieved, but installation is labor-intensive and requires specialized tools
Solution Approach 1:
The connector is divided into separate plug and receptacle assemblies, each with independent locking mechanisms. The locking collar can be operated independently to secure or release the connection, simplifying installation and maintenance operations while maintaining robust connectivity.
Solution Approach 2:
The connector incorporates self-aligning features and a self-locking mechanism that engages automatically when components are mated. The flexible fingers and locking collar work together to secure the connection without requiring specialized tools or multiple installers, reducing installation complexity while ensuring reliable connection.
2Reliability
If connectors are made robust to withstand vibration, then connection integrity is maintained, but weight increases
Solution Approach 1:
The locking collar is designed to rotate between locked and unlocked positions, providing dynamic control over the connection state. The flexible fingers adapt to alignment variations during mating, creating a robust connection that can withstand vibration while using minimal material, thus controlling weight.
Solution Approach 2:
The locking collar rotates around the finger collar, with the locking mechanism nested within the overall connector structure. This nested arrangement provides robust vibration resistance through multiple engagement points while minimizing the overall footprint and material usage, keeping weight down.
3Volume of moving object
If wiring and connectors are made compact to save space, then space efficiency improves, but installation and repair difficulty increases
Solution Approach 1:
The connector is segmented into modular plug and receptacle components that can be independently handled and installed. The locking collar operates independently to secure the connection, allowing installers to work with smaller, more manageable components in tight spaces while maintaining ease of operation through simple locking and unlocking actions.
Solution Approach 2:
The self-aligning features and automatic locking mechanism allow the compact connector to install itself with minimal manual intervention. The flexible fingers and locking collar work together to secure the connection automatically when mated, reducing installation difficulty despite the compact size that would otherwise make manual manipulation challenging.
4Strength
If pin and socket connections are used for robust connectivity, then connection strength improves, but connector size increases
Solution Approach 1:
The locking collar rotates to dynamically change the engagement state between locked and unlocked positions. This dynamic mechanism provides strong mechanical engagement through the flexible fingers and locking collar interaction while maintaining a compact form factor, achieving high connection strength without increasing connector volume.
Solution Approach 2:
The locking collar is nested around the finger collar, with the locking mechanism integrated within the overall connector structure. This nested arrangement provides strong mechanical connection through multiple engagement points while minimizing the overall connector volume, achieving robust connectivity in a compact package.
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
Provides a robust, compact, and efficient electrical connection that can withstand aircraft vibrations, allows rapid repairs, and reduces installation complexity, all while maintaining alignment and integrity.
Implementation Method 1
The finger collar includes one or more flexible fingers that are positioned around the finger collar and are configured to flex to engage the pin assembly when it is mated with the socket assembly
Data Source
AI summary
An electrical connector assembly for use with conductors includes a pin assembly with a pin and a socket assembly to mate with the pin assembly. The socket assembly includes a socket body configured to receive the pin. A finger collar surrounds the socket body, and a locking collar surrounds and is rotatable on the finger collar. The locking collar moves between an unlocked position and a locked position. The finger collar includes one or more flexible fingers configured to flex to engage the pin assembly when it is mated with the socket assembly. The locking collar includes one or more windows that are in alignment with respective flexible fingers so the flexible fingers lex through the locking collar to engage the pin assembly and flex and grasp the pin assembly. The locking collar is further rotatable to the locked position that moves the windows out of alignment with the respective flexible fingers and prevents further flexing of the flexible fingers away from the pin assembly to lock the socket assembly in engagement with the pin assembly.