Modular Train Coupler Connector With Replaceable Contact Units
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Solution Overview
Problem
Current train coupler connector systems are costly and time-consuming to maintain due to the high expense of replacing individual connectors and the complexity of replacing larger modules, which requires dismantling the contact block and reconnection of cables.
Innovation Solution
A modular train coupler connector system where a fixing block holds contact units with both female and male ends, allowing for easy replacement of individual contact units without disassembling the entire module, and a protective lid covers the module to prevent wear and dirt exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual connectors are replaced, then the electrical connection can be restored, but the cost for each replacement is high
Solution Approach 1:
The electrical connector is divided into two main segments: a reusable contact block and replaceable contact units. The contact block contains the insulating body with embedded contact holders, while the contact units consist of male and female contacts that can be independently replaced. This segmentation allows the expensive contact block to be reused while only replacing the cheaper contact units, thereby reducing replacement costs while maintaining electrical connection reliability.
Solution Approach 2:
The contact units are designed as disposable or easily replaceable components with lower cost compared to the entire connector assembly. When contacts wear out or fail, only these cheaper contact units need to be replaced rather than the entire connector block, reducing the cost burden of maintenance while ensuring continuous electrical connection.
2Ease of manufacture
If larger modules are used, then the cost per replacement decreases, but the replacement process becomes cumbersome and time-consuming
Solution Approach 1:
The connector is segmented into a permanent contact block and removable contact units. The contact units can be individually extracted from the contact block without dismantling the entire module, allowing for quick replacement of only the faulty contacts while keeping the reusable contact block in place, thus reducing replacement time while maintaining cost efficiency.
Solution Approach 2:
The contact units are designed with dynamic replaceability - they can be easily inserted and removed from the contact block through a simple extraction and insertion process. This dynamic design allows maintenance personnel to quickly swap out faulty contact units without committing to replacing entire large modules, significantly reducing the time required for replacement operations.
3Ease of operation
If contacts are divided into contact holder and contact member, then maintenance is eased, but the cost for individual connectors remains high
Solution Approach 1:
The contact assembly is segmented into a reusable contact holder (integrated with the insulating contact block) and replaceable contact members (male and female contacts). This segmentation maintains the ease of maintenance benefit by allowing contact members to be replaced independently, while also addressing the cost issue by making the contact holders permanent and reusable, thereby reducing the frequency and cost of replacements.
4Adaptability or versatility
If the same contact units are used for both male and female configurations, then the number of connector types is reduced, but the design complexity increases
Solution Approach 1:
The contact units are designed with universal functionality - the same basic contact unit design can serve as either male or female contact depending on its orientation and configuration within the contact block. This universality reduces the number of different connector types needed in the system, simplifying inventory and maintenance, while the modular design allows flexible arrangement to achieve different polarizations without increasing overall design complexity.
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3c
AI summary
The present invention relates to a train coupler connector module (1) for electrically coupling a first rail vehicle to a second rail vehicle, the module comprising: -a fixing block (11) with an inner side able to be mounted on an electrical train coupler, -a plurality of contact units (3) arranged side by side in the fixing block (11), each contact unit (3) having a first end (32) facing the inner side of the fixing block (11) and a second end (33) extending outwards from the fixing block (11), one of the first and second end being a female contact (24) and the other being a male contact (25), -wherein at least one of the contact units (3) is arranged to be individually removable from the fixing block (11) in a direction outwards from the fixing block (11).