Variable Pitch Gear Axial Connector Mating Force Control
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Solution Overview
Problem
Existing electrical connectors with integral lever mechanisms require cumbersome multi-step mating processes, are not ergonomically friendly, prone to mating damage or mis-mating, and occupy additional space, limiting the number of terminals.
Innovation Solution
An axial mate-assist system utilizing an involute curved non-circular gear with a variable pitch-radius, which provides a high mechanical advantage during peak mating forces, reducing the peak mating force and allowing for a constant mating force throughout the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If an integral lever mechanism is used for mate-assist, then the connector can achieve mechanical advantage during mating, but the mating process becomes cumbersome and requires prepositioning steps
Solution Approach 1:
The patent extracts the lever mechanism from the connector assembly, separating the mate-assist function into a standalone device. This allows the lever to be applied after alignment rather than requiring prepositioning, simplifying the mating process while maintaining mechanical advantage during the actual connection
Solution Approach 2:
The patent applies preliminary alignment actions (bringing connectors into approximate alignment) before applying the lever mechanism. This separates the alignment phase from the mating phase, allowing operators to prepare connectors without committing to full engagement, thereby reducing complexity
2Force
If a lever mechanism with tools is used during mating, then mechanical advantage is achieved, but additional application package space is required
Solution Approach 1:
The patent segments the mating system into modular components: alignment features on the connectors themselves, and a separate lever mechanism that can be stored independently. This segmentation allows the main connector bodies to remain compact while the lever mechanism provides the necessary mechanical advantage when needed
Solution Approach 2:
The patent introduces an intermediary lever mechanism that transfers force from the operator to the connector terminals. This intermediary device provides mechanical advantage without requiring the connectors themselves to be larger, as the lever is a separate tool that interfaces with existing connector features
3Force
If traditional mate-assist mechanisms are used, then mechanical advantage is provided, but the system is prone to mating damage and mis-mating
Solution Approach 1:
The patent implements preliminary alignment features including guide pins and alignment slots that ensure connectors are properly positioned before the lever mechanism is applied. This preliminary action prevents mis-mating by establishing correct alignment prior to engagement
Solution Approach 2:
The patent incorporates cushioning elements and controlled engagement features that prevent damage during mating. The lever mechanism is designed to apply force gradually and controllably, cushioning against sudden impacts or mis-alignments that could cause damage to the connectors or terminals
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 system simplifies the mating process, reduces the risk of damage or mis-mating, and increases the number of terminals possible in the connector by maintaining a uniform mating force, enhancing ergonomics and efficiency.
Implementation Method 1
an axial mate-assist system that utilizes an involute curved non-circular gear with a variable pitch-radius. The variable-pitch-radius gear is configured to provide high mechanical advantage when the connection system components are experiencing their highest mating-forces
Implementation Method 2
The round-gear engages the linear-gear-rack within the guide-slot. Rotation of the round-gear engaged with the linear-gear-rack axially pulls the linear-gear-rack into the guide-slot, thereby pulling the second-housing into the first-housing
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A connector (10) includes a first-housing (12), a second-housing (18), a shroud (24), and a stacked-gear (34). The stacked-gear (34) is moveably mounted to the first-housing (12). The stacked-gear (34) engages a first-gear-rack (20) on the second-housing (18) and a second-gear-rack (30) on the shroud (24). The second-housing (18) is mated with the first-housing (12) when the shroud (24) is moved along a mating-axis (25) of the connector (10). The stacked-gear (34) engages at least two teeth on the first-gear-rack (20) and on the second-gear-rack (30) when the second-housing (18) is mated with the first-housing (12). A rotation (40) of the stacked-gear (34) is greater than ninety degrees when the shroud (24) is moved from an unmated-position (26) to a mated-position (28). The stacked-gear (34) initially engages a first-side (70) of a first-tooth (72) of the first-gear-rack (20) when the first-housing (12) receives the second-housing (18). A uniform mating-force is maintained as the shroud (24) is moved from an unmated-position (26) to a mated-position (28). A mechanical advantage to produce the mating-force is increased as the shroud (24) is moved from an unmated-position (26) to a mated-position (28).