Modular Wiring Locking Mechanism for Secure Alignment
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Solution Overview
Problem
Existing modular wiring systems lack a secure and intuitive method for coupling functional units to wiring units, often resulting in miswiring and inefficient connections.
Innovation Solution
A modular wiring system featuring a locking mechanism with electrically conductive prongs and flanges that allow for rotational coupling, ensuring secure and correct alignment of functional and wiring units through a locking connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wiring connection methods are used, then installation flexibility is maintained, but connection security and alignment precision deteriorate leading to miswiring
Solution Approach 1:
The connection mechanism is divided into separate functional components: locking elements with prongs for electrical connection, flanges for mechanical support, and a rotational coupling system. This segmentation allows each component to perform its specific function optimally while maintaining overall system precision.
Solution Approach 2:
The locking elements feature asymmetric prong configurations and non-circular cross-sections that provide unique orientation cues. This asymmetry ensures that functional units can only be connected in the correct rotational position, preventing miswiring while guiding proper alignment during installation.
2Reliability
If simple connection methods are used, then ease of operation is improved, but connection reliability deteriorates
Solution Approach 1:
The locking elements and flanges are pre-configured in specific geometric arrangements that automatically guide the connection process. The prongs are pre-positioned to engage with corresponding receptacles, and flanges are pre-oriented to provide mechanical guidance, ensuring reliable connection without requiring complex alignment procedures by the installer.
Solution Approach 2:
The rotational coupling mechanism with locking elements performs self-alignment during the connection process. As the functional unit is rotated into place, the asymmetric prongs automatically orient themselves to the correct position and lock into the wiring unit, providing self-verifying connection reliability without requiring external alignment tools or complex procedures.
3Strength
If rotational coupling with locking elements is implemented, then connection security is improved, but device complexity increases
Solution Approach 1:
The locking elements combine multiple functions into a single integrated component: electrical conduction through conductive prongs, mechanical locking through the rotational engagement of the body, and alignment guidance through asymmetric geometry. This merging reduces the need for separate fasteners, electrical connectors, and alignment features, simplifying the overall mechanism while maintaining strong connections.
Solution Approach 2:
The locking elements utilize composite construction combining electrically conductive materials for the prongs with mechanically strong materials for the body and flanges. This composite approach allows the same component to simultaneously provide electrical connectivity and mechanical strength, achieving robust connections without requiring additional specialized parts.
Data Source
AI summary
A wiring system includes a wiring module and a functional module. The wiring module in at least one embodiment includes elongated holes or openings which are configured to engage or lock with prongs on a functional module to create a lockable connection. The wiring module and the functional module form both a physical and an electrical connection. In another embodiment, there is an adapter which is configured to connect the wiring module and the functional module or unit together.