Vehicle Trailer Plug Assembly Radial Connector Cavities
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Solution Overview
Problem
The incompatibility between tow vehicles and trailers with different numbers of electrical connectors in vehicle-trailer wiring connector assemblies leads to difficulties in communication of electrical signals, requiring multiple receptacle assemblies for compatibility.
Innovation Solution
A connector assembly is configured to enable interface between plug assemblies and receptacle assemblies with varying numbers of electrical connectors, featuring a plug assembly with six radially disposed connector cavities and additional electrical connectors that are electrically insulated, allowing compatibility with different standards such as SAE J2863 and additional systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug assembly is designed with a fixed number of electrical connectors according to a specific standard (e.g., SAE J2863), then it ensures compatibility with receptacle assemblies of that standard, but it becomes incompatible with receptacle assemblies of different standards or with varying numbers of connectors
Solution Approach 1:
The plug assembly is designed to accommodate multiple connector configurations within a single standardized housing. The six radially disposed connector cavities can accept various types of electrical connectors (blade-style, round, different pin counts) according to different standards (SAE J2863, SAE J560b, custom configurations), allowing one plug assembly to interface with multiple receptacle assembly types.
Solution Approach 2:
The plug assembly divides the connector interface into six separate radially disposed connector cavities, each capable of independently accepting different types of electrical connectors. This segmentation allows each cavity to be configured for specific connector types while maintaining overall compatibility with various standard arrangements.
2Reliability
If electrical connectors are positioned within connector cavities to ensure proper alignment and connection, then reliable electrical contact is achieved, but the connectors become difficult to access and replace
Solution Approach 1:
The electrical connectors are nested within the plug housing in radially disposed connector cavities. This nesting protects the connectors while allowing them to be accessed by removing the plug assembly from the receptacle, at which point the connectors become accessible for replacement or maintenance.
3Strength
If electrical connectors are disposed internally within the plug housing to protect them from damage, then connector durability is improved, but the plug assembly becomes more complex in structure
Solution Approach 1:
The connector cavities are radially disposed around a central axis, creating a symmetrical, circular pattern that simplifies the overall housing structure. This radial arrangement naturally protects connectors while maintaining a compact, standardized form factor that fits within conventional receptacle assemblies.
Data Source
AI summary
A plug assembly for a vehicle-trailer wiring connector assembly includes a plug housing, six connector cavities, and a first and second electrical connectors. The plug housing is positionable in a receptacle assembly. The six connector cavities are defined in and radially disposed around a connecting face of the plug housing in compliance with the Society of Automotive Engineers J2863 standard. The first electrical connector is positioned with respect to a first connector cavity of the cavities. A first contact surface of the first electrical connector is contactable within the first connector cavity. The second electrical connector is positioned with respect to the plug housing. A second contact surface of the second electrical connector is substantially aligned with an outer surface of the plug housing and externally contactable. The second electrical connector is positioned relative to the first electrical connector such that the second electrical connector is electrically insulated therefrom.