Solenoid-Actuated Electrical Connector Release Restriction
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Solution Overview
Problem
Conventional electrical connectors with solenoid-based release mechanisms are prone to failure when the release lever is forcibly operated while restricted, leading to potential electric leakage during charging.
Innovation Solution
The electrical connector design incorporates a solenoid with a plunger that moves a release restricting portion, which is pressed by a coil spring and not fixed to the plunger, distributing forces to prevent solenoid failure, and includes a release button with a projecting portion to restrict movement and enhance abutment area, ensuring the solenoid is less likely to fail under forced operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the release portion is fixed using a solenoid with a pin connection, then the release portion can be reliably restricted, but the solenoid becomes vulnerable to failure under forced operation
Solution Approach 1:
A force transmission member is introduced as an intermediary between the release lever and the plunger. This member transmits the restricting force while being replaceable, protecting the solenoid from direct damage during forced operation attempts.
Solution Approach 2:
The force transmission member is designed as a sacrificial, replaceable component that can absorb the damage from forced operation attempts, while the expensive solenoid remains protected and reusable.
2Ease of operation
If the release lever can be freely operated, then ease of operation is improved, but the risk of unintended release during charging increases
Solution Approach 1:
The system dynamically switches between locked and unlocked states based on charging status. During charging, the release portion is restricted; when charging is complete, the restriction is released, allowing safe disconnection.
Solution Approach 2:
The control unit monitors charging status and automatically controls the solenoid to restrict or release the release portion accordingly, providing feedback-based safety control.
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 design enhances the solenoid's resistance to failure, preventing unintended release and ensuring secure locking during charging, thereby reducing the risk of electric leakage and improving connector reliability.
Implementation Method 1
a solenoid 131 that moves the release restricting portion 135
Implementation Method 2
a coil spring 137 that presses the release restricting portion 135
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A connector (1) includes a locking lever (104) that locks a fitted state with an inlet (2), a release button (105A) that is provided to be movable in Z-direction positive and negative directions and rotates the locking lever (104) by moving in the Z-direction negative direction to release the locking, a release restricting portion (135) that is provided to be movable in X-direction positive and negative directions and to be movable to an abutting position (PL) where the release restricting portion (135) abuts against the release button (105A), thereby restricting the movement in the Z-direction negative direction of the release button (105A) at the abutting position (PL) to restrict the release of the locking, a solenoid (131) as a moving portion that moves the release restricting portion (135) in the X-direction negative direction, and a coil spring (137) that presses the release restricting portion (135) in the X-direction positive direction.