New energy automobile high-power connector and application thereof

Abstract

The invention relates to the technical field of high-power connectors, and provides a new energy automobile high-power connector and application thereof, and the new energy automobile high-power connector comprises a support frame plate which is fixedly connected with a new energy automobile body; a tightening mechanism is arranged on the outer surface of the connecting main end; the auxiliary connecting end is in butt joint with the main connecting end, the auxiliary connecting end and the main connecting end are fixed through a connecting assembly, a damping spring is arranged on the outer surface of the main connecting end, the end, away from the main connecting end, of the damping spring is fixedly connected with the outer surface of the supporting frame plate, and the main connecting end and the auxiliary connecting end are in butt joint; the energy of the power supply is efficiently transmitted to the load so as to drive the new energy automobile to run, vibration generated in the high-speed running process of the new energy automobile can be absorbed by the damping spring, meanwhile, the tightening mechanism protects the connecting assembly in real time, and loosening generated when the main connecting end and the auxiliary connecting end are in butt joint is avoided.

Description

Technical Field

[0001] This invention relates to the field of high-power connector technology, and in particular to a high-power connector for new energy vehicles and its application. Background Technology

[0002] With the popularization of 800V high-voltage platforms and the upgrading of power performance in new energy vehicles, sport mode has become a core function to enhance the driving experience. When switching from leisure mode to sport mode while driving, the motor output power and instantaneous current will increase significantly (e.g., peak current increases from 350A to 400A). As a core transmission component of the high-voltage system, the high-power connector needs to continuously bear large currents and ensure the stability of circuit conduction. However, during driving, the entire vehicle faces a wide frequency vibration of 10-150Hz (including road bumps, motor resonance, etc.). Rapid acceleration and high-frequency operating conditions in sport mode will further aggravate the vibration impact, which can easily lead to micro-displacement of connector contacts, fatigue of elastic components, or loosening of locking mechanisms, causing problems such as increased contact resistance and instantaneous power failure. In severe cases, it can cause electric arcing, excessive temperature rise, and even affect the continuity of power output and the high-voltage safety of the entire vehicle. Existing traditional connectors use a locking structure for fixation, but with continuous broadband vibration, the locking structure will still loosen, and the stability of the structure cannot be guaranteed. Summary of the Invention

[0003] The purpose of this invention is to solve the problem that new energy vehicles generate wide-frequency vibrations during operation, which can lead to micro-displacement of connector contacts, fatigue of elastic components, or loosening of locking mechanisms, resulting in increased contact resistance and momentary power outages. This invention provides a high-power connector for new energy vehicles and its application.

[0004] The technical solution adopted by the present invention to solve its technical problem is: a high-power connector for new energy vehicles, comprising: a support frame plate, wherein the support frame plate is fixedly connected to the body of the new energy vehicle; A main connection end is provided with a tightening mechanism on its outer surface; A connecting sub-end is connected to the connecting main end. The connecting sub-end and the connecting main end are fixed together by a connecting assembly. A damping spring is provided on the outer surface of the connecting main end. The end of the damping spring away from the connecting main end is fixedly connected to the outer surface of the support frame plate. The main connection terminal is connected to the load, and the secondary connection terminal is connected to the power supply. During high-speed driving, the vibrations generated by new energy vehicles are absorbed by damping springs, while the tightening mechanism provides real-time protection for the connecting components to prevent loosening when the main and secondary connecting ends are connected.

[0005] Furthermore, the tightening mechanism includes a micro motor, the output end of which is fixedly connected to a rotating shaft, and the end of the rotating shaft away from the micro motor is fixedly connected to a first transmission disc, the outer surface of which is fitted with a transmission track. The tightening mechanism also includes a knob mechanism, which is connected to the connecting assembly.

[0006] Furthermore, the knob mechanism includes a miniature electric cylinder, the output end of which is rotatably connected to a rotating block, the outer surface of which is fixedly connected to a second transmission disk, a cross groove being provided on the side of the rotating block away from the miniature electric cylinder, and a miniature camera being fixedly connected to the outer surface of the second transmission disk.

[0007] Furthermore, the transmission track needs to be simultaneously fitted onto the first transmission disc and the second transmission disc.

[0008] Furthermore, the main connection includes an insulating main board, a docking main board is fixedly connected to the outer surface of the insulating main board, a converter is fixedly connected to the side of the insulating main board away from the docking main board, a first docking member is fixedly connected to the outer surface of the converter, a first wire is also fixedly connected to the outer surface of the converter, a threaded groove is provided on the outer surface of the docking main board, and a sealing end is provided at the end of the docking main board away from the insulating main board.

[0009] Furthermore, the chassis of the micro motor is fixedly connected to the bottom of the insulating main board, the chassis of the micro electric cylinder is fixedly connected to the outer surface of the insulating main board, and the first docking member is located inside the docking main tube.

[0010] Furthermore, the connecting end includes a secondary connecting tube, a second connecting member is fixedly connected to the outer surface of the secondary connecting tube, a second wire is fixedly connected to the end of the secondary connecting tube away from the second connecting member, an outer plate is fixedly connected to the end of the secondary connecting tube close to the second connecting member, insertion holes are uniformly arranged on the outer surface of the outer plate, and a sealing groove adapted to the sealing end is also provided on the inner side of the outer plate.

[0011] Furthermore, high-power energy transmission is achieved by inserting the first docking member into the docking main tube and making contact with the second docking member.

[0012] Furthermore, the connecting assembly includes a threaded rod, one end of which is fixedly connected to a screw head, and the other end of the threaded rod away from the screw head is fixedly connected to a cross block; The threaded rod is adapted to the threaded groove, and the cross block is adapted to the cross groove.

[0013] An application of a high-power connector for new energy vehicles includes the following steps: S1: Insert the secondary connector into the primary connector and install the connector assembly between the secondary connector and the primary connector to achieve high-efficiency power transmission; S2: As the vehicle moves, the damping spring absorbs vibrations and prevents the connecting components from loosening; S3: The tightening mechanism detects the tightness of the connecting components and tightens them if they become loose.

[0014] The beneficial effects of the high-power connector for new energy vehicles and its application provided by this invention are as follows: (1) By setting damping springs around the main connection end, the vibration generated by the new energy vehicle during driving is absorbed, reducing the possibility of loosening of the connection components; (2) Since the damping spring can only reduce the loosening of the connecting components but cannot completely eliminate it, a tightening mechanism is set up. When the loosening of the connecting components is detected, the micro motor will drive the rotating shaft and the first transmission disk to rotate, thereby driving the second transmission disk to rotate, which in turn causes the rotating block and the cross block embedded in the cross groove to rotate, thereby driving the threaded rod to rotate, and then tightening the threaded rod again. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural front view of the present invention; Figure 2 This is a rear view of the three-dimensional structure of the present invention; Figure 3 This is a three-dimensional structural separation diagram of the present invention; Figure 4 This is a schematic diagram of the structure connecting the main end of the present invention; Figure 5 This is a schematic diagram of the tightening mechanism of the present invention; Figure 6 This is a schematic diagram of the knob mechanism of the present invention; Figure 7 This is a schematic diagram of the structure of the connecting component of the present invention; Figure 8 This is a schematic diagram of the structure of the connecting sub-end of the present invention.

[0016] In the diagram: 1. Support frame plate; 2. Damping spring; 3. Main connecting end; 4. Tightening mechanism; 5. Connecting assembly; 6. Secondary connecting end; 31. Insulating main plate; 32. Main connecting pipe; 33. First connecting piece; 34. Threaded groove; 35. Sealing end; 36. Converter; 37. First wire; 41. Micro motor; 42. Rotating shaft; 43. First transmission disc; 44. Knob mechanism; 45. Transmission track; 441. Micro electric cylinder; 442. Rotating block; 443. Cross groove; 444. Second transmission disc; 445. Micro camera; 51. Threaded rod; 52. Tightening head; 53. Cross block; 61. Secondary connecting pipe; 62. Second wire; 63. Second connecting piece; 64. Outer plate; 65. Sealing groove; 66. Insertion hole. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the further embodiments described herein are merely illustrative and not intended to limit the invention.

[0018] To ensure the stable operation of high-power connectors under the combined conditions of wide-band vibration and high-current transmission, it is necessary to overcome the limitations of optimizing single components and form a systematic solution through multi-structure collaborative design. To address how to prevent micro-displacement of connector contacts, fatigue of elastic components, or loosening of locking mechanisms caused by wide-band vibration, and to remedy such displacement, it is necessary to start from the overall structural compatibility and organically link functional modules such as buffering, fastening, conductivity, and sealing. The following details the specific optimization design from the perspective of structural collaboration.

[0019] like Figures 1-3 As shown, a high-power connector for new energy vehicles includes: a support frame plate 1, which is fixedly connected to the body of the new energy vehicle. It is made of 5-series aluminum alloy and is integrally die-cast with a thickness of 3mm. It combines lightweight and high strength (tensile strength ≥320MPa) and can withstand the continuous impact of the vehicle body under 150Hz high-frequency vibration. The main end 3 is connected, and a tightening mechanism 4 is provided on the outer surface of the main end 3. The connecting sub-end 6 is connected to the connecting main end 3. The connecting sub-end 6 and the connecting main end 3 are fixed together by the connecting component 5. The outer surface of the connecting main end 3 is provided with a damping spring 2. The damping spring 2 is made of 60Si2Mn high-strength spring steel, which effectively reduces the impact of vibration on the connecting component 5. The end of the damping spring 2 away from the connecting main end 3 is fixedly connected to the outer surface of the support frame plate 1. Connect the main terminal 3 to the load and the secondary terminal 6 to the power supply; First, the main connection 3 and the secondary connection 6 are connected to the load so that the power supply can be efficiently transferred to drive the new energy vehicle. During the high-speed driving of the new energy vehicle, the vibration generated will be absorbed by the damping spring 2. At the same time, the tightening mechanism will protect the connection component 5 in real time to prevent loosening when the main connection 3 and the secondary connection 6 are connected.

[0020] like Figure 4 As shown, the main connection 3 includes an insulating main board 31. A docking main board 32 is fixedly connected to the outer surface of the insulating main board 31. A converter 36 is fixedly connected to the side of the insulating main board 31 away from the docking main board 32. The converter 36 has a built-in manganese copper shunt and a high-frequency filter capacitor, which can monitor the transmission current in real time and suppress high-frequency interference. A first docking member 33 is fixedly connected to the outer surface of the converter 36. The first docking member 33 is made of beryllium bronze substrate and plated with 5μm hard gold. A first wire 37 is also fixedly connected to the outer surface of the converter 36. A threaded groove 34 is provided on the outer surface of the docking main board 32. A sealing end 35 is provided at the end of the docking main board 32 away from the insulating main board 31.

[0021] The chassis of the micro motor 41 is fixedly connected to the bottom of the insulating main board 31, the chassis of the micro electric cylinder 441 is fixedly connected to the outer surface of the insulating main board 31, and the first docking part 33 is located inside the docking main tube.

[0022] like Figure 8 As shown, the connecting end includes a secondary connecting tube 61. A second connecting piece 63 is fixedly connected to the outer surface of the secondary connecting tube 61. The second connecting piece 63 is an elastic clip-type structure that forms multi-point contact with the first connecting piece 33 to ensure stable conduction under vibration. A second wire 62 is fixedly connected to the end of the secondary connecting tube 61 away from the second connecting piece 63. An outer plate 64 is fixedly connected to the end of the secondary connecting tube 61 close to the second connecting piece 63. Insertion holes 66 are evenly arranged on the outer surface of the outer plate 64. A sealing groove 65 that matches the sealing end 35 is also provided on the inner side of the outer plate 64. A fluororubber O-ring is embedded between the sealing end 35 and the sealing groove 65.

[0023] When installing the connector, the secondary docking tube 61 and the main docking tube 32 must first be connected, and the second docking part 63 must be brought into contact with the first docking part 33. At the same time, the sealing end 35 will enter the sealing groove 65 to prevent impurities and moisture in the air from entering the secondary docking tube 61 and the main docking tube 32 during energy transmission.

[0024] High-power energy transmission is achieved by inserting the first docking member 33 into the docking main tube 32 and making contact with the second docking member 63.

[0025] like Figure 7As shown, the connecting assembly 5 includes a threaded rod 51, one end of which is fixedly connected to a screw head 52, and the other end of the threaded rod 51 away from the screw head 52 is fixedly connected to a cross block 53. The cross block 53 is made of PEEK (polyether ether ketone) material, which has self-lubricating and insulating properties, and avoids forming a conductive path with metal parts. The cross block 53 can be disassembled to facilitate the installation of the threaded rod 51. After the docking is completed, threaded rod 51 is passed through insertion hole 66 and rotated into threaded groove 34. Then cross block 53 is installed to fix docking main tube 32 and docking secondary tube 61.

[0026] The threaded rod 51 is adapted to the threaded groove 34, and the cross block 53 is adapted to the cross groove 443.

[0027] like Figure 5 As shown, the tightening mechanism includes a micro motor 41, the output end of the micro motor 41 is fixedly connected to a rotating shaft 42, the end of the rotating shaft 42 away from the micro motor 41 is fixedly connected to a first transmission disc 43, and a transmission track 45 is sleeved on the outer surface of the first transmission disc 43. The tightening mechanism also includes a knob mechanism 44, which is connected to the connecting assembly 5.

[0028] like Figure 6 As shown, the knob mechanism 44 includes a miniature electric cylinder 441. The output end of the miniature electric cylinder 441 is rotatably connected to a rotating block 442. A second transmission disk 444 is fixedly connected to the outer surface of the rotating block 442. A cross groove 443 is provided on the side of the rotating block 442 away from the miniature electric cylinder 441. A miniature camera 445 is fixedly connected to the outer surface of the second transmission disk 444. The miniature camera 445 is a high-definition industrial camera equipped with an infrared fill light, which can identify the displacement of the cross block 53 in the dim environment of the cabin.

[0029] The transmission track 45 needs to be simultaneously fitted onto the first transmission disc 43 and the second transmission disc 444.

[0030] After the threaded rod 51 is installed, the miniature electric cylinder 441 will extend one end and make the cross block 53 fully enter the cross groove 443. At this time, the first transmission disc and the second transmission disc will be in the same vertical plane. Then the transmission track 45 will be put on the first transmission disc and the second transmission disc.

[0031] When the threaded rod 51 becomes loose due to vibration, the miniature camera 445 will detect that the cross block 53 has moved a certain distance from the cross groove 443. Then, the miniature motor 41 will drive the rotating shaft 42 and the first transmission disk 43 to rotate, thereby driving the second transmission disk 444 to rotate, which in turn causes the rotating block 442 and the cross block 53 embedded in the cross groove 443 to rotate, thereby driving the threaded rod 51 to rotate, and thus tightening the threaded rod 51 again.

[0032] The present invention provides a high-power connector for new energy vehicles and its application process: First, the secondary connecting tube 61 and the main connecting tube 32 need to be connected, and the second connecting part 63 needs to be in contact with the first connecting part 33. At the same time, the sealing end 35 will enter the sealing groove 65 to prevent impurities and moisture in the air from entering the secondary connecting tube 61 and the main connecting tube 32 during energy transmission. After the connection is completed, the threaded rod 51 is passed through the insertion hole 66 and rotated into the threaded groove 34. Then, the cross block 53 is installed to fix the main connecting tube 32 and the secondary connecting tube 61. After the threaded rod 51 is installed, the miniature electric cylinder 441 will extend one end and move the cross block. When the cross block 53 is fully inserted into the cross groove 443, the first and second transmission discs will be in the same vertical plane. Then, the transmission track 45 is put on the first and second transmission discs. When the miniature camera 445 detects that the cross block 53 has moved a certain distance from the cross groove 443, the miniature motor 41 will drive the rotating shaft 42 and the first transmission disc 43 to rotate, thereby driving the second transmission disc 444 to rotate, which in turn causes the rotating block 442 and the cross block 53 embedded in the cross groove 443 to rotate, thereby driving the threaded rod 51 to rotate, and then tightening the threaded rod 51 again.

[0033] An application of a high-power connector for new energy vehicles includes the following steps: S1: Insert the secondary connector 6 into the primary connector 3, and install the connector component 5 between the secondary connector 6 and the primary connector 3 to achieve high-efficiency power transmission; S2: As the vehicle moves, the damping spring 2 absorbs vibrations to prevent the connecting assembly 5 from becoming loose; S3: The tightening mechanism 4 will detect the tightness of the connecting component 5 and tighten the connecting component 5 when it becomes loose.

[0034] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the term "fixed connection" should be interpreted broadly. For example, it can refer to a bolted connection, a welded connection, or an integral connection; it can refer to a mechanical connection or an electrical connection; it can refer to a direct connection or an indirect connection through an intermediate medium; it can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.

[0035] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-power connector for new energy vehicles and its application, characterized in that, include: A support frame plate, which is fixedly connected to the body of the new energy vehicle; A main connection end is provided with a tightening mechanism on its outer surface; A connecting sub-end is connected to the connecting main end. The connecting sub-end and the connecting main end are fixed together by a connecting assembly. A damping spring is provided on the outer surface of the connecting main end. The end of the damping spring away from the connecting main end is fixedly connected to the outer surface of the support frame plate. The main connection terminal is connected to the load, and the secondary connection terminal is connected to the power supply. During high-speed driving, the vibrations generated by new energy vehicles are absorbed by damping springs, while the tightening mechanism provides real-time protection for the connecting components to prevent loosening when the main and secondary connecting ends are connected.

2. The high-power connector for new energy vehicles and its application according to claim 1, characterized in that: The tightening mechanism includes a micro motor, the output end of which is fixedly connected to a rotating shaft, and the end of the rotating shaft away from the micro motor is fixedly connected to a first transmission disc, and a transmission track is sleeved on the outer surface of the first transmission disc. The tightening mechanism also includes a knob mechanism, which is connected to the connecting assembly.

3. The high-power connector for new energy vehicles and its application according to claim 2, characterized in that: The knob mechanism includes a miniature electric cylinder, the output end of which is rotatably connected to a rotating block. A second transmission disk is fixedly connected to the outer surface of the rotating block. A cross groove is provided on the side of the rotating block away from the miniature electric cylinder. A miniature camera is fixedly connected to the outer surface of the second transmission disk.

4. The high-power connector for new energy vehicles and its application according to claim 3, characterized in that: The transmission track needs to be simultaneously fitted onto the first transmission disc and the second transmission disc.

5. A high-power connector for new energy vehicles and its application according to claim 3, characterized in that: The main connection includes an insulating main board, a docking main board is fixedly connected to the outer surface of the insulating main board, a converter is fixedly connected to the side of the insulating main board away from the docking main board, a first docking component is fixedly connected to the outer surface of the converter, a first wire is also fixedly connected to the outer surface of the converter, a threaded groove is provided on the outer surface of the docking main board, and a sealing end is provided at the end of the docking main board away from the insulating main board.

6. A high-power connector for new energy vehicles and its application according to claim 5, characterized in that: The chassis of the micro motor is fixedly connected to the bottom of the insulating main board, the chassis of the micro electric cylinder is fixedly connected to the outer surface of the insulating main board, and the first docking component is located inside the docking main tube.

7. A high-power connector for new energy vehicles and its application according to claim 6, characterized in that: The connecting end includes a secondary connecting tube, a second connecting member is fixedly connected to the outer surface of the secondary connecting tube, a second wire is fixedly connected to the end of the secondary connecting tube away from the second connecting member, and an outer plate is fixedly connected to the end of the secondary connecting tube close to the second connecting member. Insertion holes are evenly arranged on the outer surface of the outer plate, and a sealing groove adapted to the sealing end is also provided on the inner side of the outer plate.

8. A high-power connector for new energy vehicles and its application according to claim 7, characterized in that: High-power energy transmission is achieved by inserting the first docking component into the docking main tube and making contact with the second docking component.

9. A high-power connector for new energy vehicles and its application according to claim 8, characterized in that: The connecting assembly includes a threaded rod, one end of which is fixedly connected to a screw head, and the other end of the threaded rod away from the screw head is fixedly connected to a cross block, which can be disassembled. The threaded rod is adapted to the threaded groove, and the cross block is adapted to the cross groove.

10. An application of a high-power connector for new energy vehicles, applicable to the high-power connector for new energy vehicles as described in any one of claims 1-9, characterized in that, Includes the following steps: S1: Insert the secondary connector into the primary connector and install the connector assembly between the secondary connector and the primary connector to achieve high-efficiency power transmission; S2: As the vehicle moves, the damping spring absorbs vibrations and prevents the connecting components from loosening; S3: The tightening mechanism detects the tightness of the connecting components and tightens them if they become loose.

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