Symmetric Cam Mate Assist for Precise Electrical Connector Alignment
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Solution Overview
Problem
Existing electrical connectors face challenges in easy mating and alignment due to asymmetric mating forces and potential misalignment, leading to increased effort, reduced reliability of electrical contact, and compromised sealing and EMI shielding continuity, especially when connecting high-power or large-section cables.
Innovation Solution
The electrical connector system employs symmetrically arranged cam members and mounting pins with opposed rotation directions, ensuring balanced torque and parallel alignment of connectors during mating, thereby reducing rocking and tilting and enhancing the robustness of the connector assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single cam member is used for mate assist, then the connector can be mated, but asymmetric mating forces cause rocking and tilting leading to misalignment
Solution Approach 1:
The patent applies asymmetry in reverse - it uses symmetry to solve an asymmetric problem. By implementing two cam members positioned symmetrically on opposite sides of the connector housing, the system balances the mating forces that were previously asymmetric. This symmetric arrangement ensures that forces are distributed evenly, preventing the rocking and tilting that occurred with a single cam member, thereby achieving both easy operation and precise alignment.
Solution Approach 2:
The second cam member acts as a counterbalance to the first cam member. When both cam members engage their respective mounting pins simultaneously, they provide counterbalancing forces that neutralize the asymmetric rocking moments. This counterweight principle ensures that the connector housing remains stable and aligned during the mating process, preventing misalignment while maintaining ease of operation.
2Power
If high power connections with large cable sections are used, then power transmission capability is improved, but cable rigidity increases making alignment difficult
Solution Approach 1:
The cam members perform preliminary alignment action before the terminals make full contact. As the connector housing approaches the mating connector, the cam members engage the mounting pins first, establishing proper alignment and orientation. This preliminary action occurs before the rigid cables and large-section terminals need to be fully positioned, making the overall mating process easier despite the cable rigidity.
Solution Approach 2:
The cam members and mounting pins serve as intermediary elements that facilitate the mating process. These intermediaries engage first and provide a mechanical guide that aligns the rigid connector housings before the cables and terminals need to be positioned. This intermediary mechanism makes it easier to mate connectors with large, rigid cables by breaking down the alignment task into manageable steps.
3Volume of moving object
If connector housing clearances are minimized, then compactness is improved, but mating efforts increase due to reduced tolerance for misalignment
Solution Approach 1:
The cam members perform preliminary alignment action before the connector housings make full contact. By engaging the mounting pins first, the cam members establish proper alignment and guide the housings into correct positioning. This preliminary action occurs while there is still some clearance between the housings, allowing alignment to be achieved before the compact, minimal-clearance configuration is finalized, thereby reducing the force needed for mating.
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 solution facilitates easier and reliable mating of connectors with balanced forces, maintaining optimal electrical contact and shielding continuity while reducing the risk of misalignment and seal pinching, thus improving the overall robustness and reliability of the connector assembly.
Implementation Method 1
a cam member rotatably mounted to the housing, comprising a cam slot for receiving a mounting pin extending from a side of a mating electrical connector
Implementation Method 2
the cam member having a gear section with teeth engaging said rack section, the engagement of the teeth with the rack section resulting in the rotation of the cam member
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
An electrical connector having - a mate assist system comprising an user actuatable member (20) which slides, along an operating direction (OD), between a rear position and a forward position, - a first (25) and a second rack sections extending parallel to the operating direction (OD), - a first and a second rotatable cam members (30) comprising a cam slot (31) for receiving a respective mounting pin (10) protruding from a mating electrical connector (2). When the user actuatable member (20) is actuated from its rear position towards its forward position, each rotatable cam member (30) engages a respective rack section (25), and the first and second cam members (30) rotate in opposed directions.