Spring-Biased Plug Connector for Reliable Electrical Connection
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Solution Overview
Problem
Existing plug connectors for electrical appliances and machine tools face challenges in maintaining a reliable, permanent electrical connection under mechanical stress, such as vibrations, due to the dependence on cable sleeves which are prone to aging and temperature-dependent spring properties.
Innovation Solution
A plug connector design featuring a separate spring element that loads the contact carrier into the contact position, providing a consistent and adjustable spring force independent of the cable sleeve, ensuring a reliable connection between the plug connector and the mating plug connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a cable sleeve is used to provide spring loading for the contact carrier, then the structure is simplified, but the spring properties become temperature-dependent and the cable sleeve is prone to aging and embrittlement
Solution Approach 1:
The invention separates the spring loading function from the cable sleeve by introducing a dedicated spring element. The cable sleeve focuses on cable protection and guidance, while the separate spring element provides consistent spring loading force, eliminating the temperature dependency and aging issues associated with using the cable sleeve as the spring mechanism.
Solution Approach 2:
A separate spring element acts as an intermediary component between the cable sleeve and the contact carrier. This intermediate spring mechanism provides the necessary spring loading force without requiring the cable sleeve itself to have spring properties, thereby decoupling the structural function from the spring function and improving reliability.
2Device complexity
If the spring element is integrated into the cable sleeve, then the number of components is reduced, but the spring force varies significantly over the lifetime of the connector
Solution Approach 1:
By segmenting the spring loading function into a separate spring element, the invention ensures that the spring force remains consistent over the lifetime of the connector. The dedicated spring element can be designed with appropriate material properties and preloading to maintain stable spring characteristics, unlike the cable sleeve which degrades over time.
Solution Approach 2:
The spring element is designed with specific material parameters and preloading conditions to optimize its spring characteristics. By selecting appropriate spring constants and preloading forces, the spring element maintains consistent spring force over time, whereas the cable sleeve's properties change due to aging and environmental factors.
3Reliability
If a separate spring element is introduced, then the spring loading consistency is improved, but the device complexity increases
Solution Approach 1:
The separate spring element serves as a specialized intermediary component that provides the spring loading function. While this adds a component, it significantly improves reliability by dedicating a specific element to spring loading, allowing for optimized material selection and design that ensures consistent performance over the connector's lifetime.
Solution Approach 2:
By introducing a separate spring element, the invention allows for optimized spring parameters (spring constant, preload, material properties) that can be specifically tuned for the application. This parameter optimization improves spring loading consistency and reliability, justifying the additional component through enhanced performance.
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 a more reliable and consistent connection by maintaining the spring force over the lifetime of the connector, reducing the impact of mechanical stress and temperature variations, thus ensuring a secure electrical link between the attachment cable and the electrical appliance.
Implementation Method 1
the contact carrier is spring-loaded with respect to the plug housing in the contact position in the direction of the plug axis by means of a spring element separate from the cable sleeve
Data Source
AI summary
A plug connector for connecting an attachment cable to a mating plug connector of an electrical appliance in the form of a vacuum cleaner, wherein the plug connector has a contact carrier having plug contacts which are connected or connectable to the attachment cable and which can be brought into an electrical contact position with mating plug contacts of the mating plug connector by a plugging movement along a plug axis, wherein the contact carrier is received, in an axially movable manner with respect to the plug axis, in a plug housing which is mounted rotatably about the plug axis with respect to the contact carrier, wherein rotary form-fit contours are arranged on the plug housing and can be brought into form-fit engagement with mating rotary form-fit contours of the mating plug connector by a rotation movement of the plug housing about the plug axis with respect to the contact carrier, such that the plug connector is secured on the mating plug connector in a tension-resistant manner with respect to the plug axis, and wherein the plug connector has a cable sleeve for the attachment cable.