Spring-Loaded Electrical Connector for Missile Launch Rail Testing
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Solution Overview
Problem
Conventional electrical connectors with detent mechanisms require significant and ergonomically challenging forces to release, leading to undesirable impact forces during initial contact mating, which can compromise contact integrity and reliability, especially in field applications where visual verification is difficult and stored energy results in uncontrolled movement.
Innovation Solution
A connector design featuring an indexing cylinder, locating pins, and tracks that allows for controlled displacement of electrical contacts using a compression spring, enabling user-friendly release and controlled impact force, with visual indicators for orientation and ease of assembly and disassembly, compatible with conventional missile launch rails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a detent mechanism is used to restrain spring-loaded electrical contacts, then the contacts can be held in a non-contact position, but significant and ergonomically challenging forces are required to release the mechanism
Solution Approach 1:
The patent replaces the static detent mechanism with a dynamic spring-loaded plunger system that automatically adjusts to contact pin positions. The plunger moves freely along the axis without requiring manual force to release, while the spring provides continuous contact pressure to maintain reliable electrical connection.
Solution Approach 2:
The spring-loaded plunger automatically engages with contact pins without requiring external actuation or manual release forces. The system self-regulates the contact pressure through spring force, eliminating the need for user-applied forces to overcome a detent mechanism.
2Ease of operation
If a detent mechanism is released, then the electrical contacts move forward to make contact, but the stored energy creates uncontrolled movement with impact forces of twelve to eighteen pounds
Solution Approach 1:
The spring-loaded plunger provides continuous, controlled contact pressure through elastic deformation of the spring. The dynamic spring system absorbs impact energy through compression, preventing the uncontrolled movement and high-impact striking forces associated with detent release mechanisms.
Solution Approach 2:
The spring element acts as a cushioning mechanism that pre-absorbs impact energy before contact is made. The spring compresses during engagement, reducing the impact force from twelve to eighteen pounds down to controlled levels that protect contact integrity.
3Adaptability or versatility
If conventional connector designs are used with multiple linear positions, then mating of electrical contacts at multiple positions is achieved, but visual verification of contact mating is not possible when contact pins are recessed
Solution Approach 1:
The patent incorporates visual indicators (such as colored bands or markers on the plunger or housing) that change position or become visible to indicate contact engagement status. This allows users to visually verify mating at multiple linear positions even when contact pins are recessed and not directly observable.
4Reliability
If large stored energy forces are used to carry loaded electrical contacts from disengaged to contact position, then reliable forward movement under loaded field conditions is achieved, but the resulting impact compromises contact integrity and reliability with repeated application
Solution Approach 1:
The spring-loaded plunger system provides continuous, controlled contact pressure through elastic spring force rather than sudden impact from stored energy release. This dynamic approach maintains reliable forward movement and contact pressure under loaded conditions while reducing impact forces that would compromise contact integrity over time.
Solution Approach 2:
The spring element cushions the engagement process by compressing during contact, reducing impact forces from twelve to eighteen pounds to controlled levels. This protection extends contact longevity by preventing damage from repeated high-impact engagement cycles.
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 controlled and reduced impact forces during contact mating, enhancing the reliability and longevity of electrical contacts and missile launch rail components by allowing controlled movement and visual verification, reducing the need for frequent replacements.
Implementation Method 1
sufficient energy to translate a plunger and electrical contacts forward into a recess of a missile launch rail using a compression spring
Data Source
AI summary
An electrical connector for testing of missile launch rail is provided. The electrical contacts of the connector move from a rear disengaged position to forward engaged positions via the energy of a compressed spring. The connector base has rail mounts for securing to a missile launch rail. A housing attaches to the base and houses a plunger, an insulator, electrical contacts, and a tube, which move forward and aft as a unit. A knob on a rear tube end enables user to limit the initial impact of the electrical contacts on contact pins or striker points of missile launch rail. The connector can provide electrical connection with launch rail pins as rail pins recede into the missile launch rail. Electrical contact position is governed, in part, by locating pins which ride in a track cut into an outer surface of the tube and move with rotation of an indexing ring.