Combined high current contact quick mounting and contact anti-loosening stabilizing method

Abstract

The application relates to the technical field of large-current electric contact connection, and discloses a combined large-current contact quick-mounting and contact anti-loosening stability method, which comprises an insulating base, and further comprises a combined conductive contact unit, a radial spring mechanism, an equal-resistance current-distribution copper bar, a contact consistency calibration structure and a foolproof and mistake-proof mounting structure which are mounted on the insulating base 1; the combined large-current contact quick-mounting is provided by using the insulating base and the foolproof and mistake-proof mounting structure, is integrally formed by using high-strength flame-retardant insulating materials, is stable in structure, reliable in insulation, sufficient in creepage distance, can bear and isolate various conductive components, and can avoid the risk of electric leakage and short circuit; standardized mounting grooves are reserved on the base, accurate positioning references are provided for various components, and assembly consistency is ensured; meanwhile, the combined large-current contact quick-mounting has vibration resistance and aging resistance, is suitable for long-term operation conditions of heavy-load AGV and AMR, and significantly improves overall safety and service life.

Description

Technical Field

[0001] This invention relates to the field of high-current electrical contact connection technology, specifically to a method for quick assembly of combined high-current contact components and a method for preventing loosening and stabilizing contacts. Background Technology

[0002] With the rapid development of heavy-duty AGVs, AMRs, and other automated equipment, the current rating of their charging systems has increased to the 200A level. As a core component for power transmission, charging contacts directly determine the equipment's operational safety, charging efficiency, and service life. Currently, high-current contacts are widely used in scenarios such as automatic charging of mobile robots and high-power electrical connections. The industry has placed higher demands on the ease of assembly, contact stability, conductivity reliability, and ease of maintenance of these contacts.

[0003] Existing 200A contact components generally suffer from several technical defects: First, assembly is complex, relying on multiple screws for fastening, requiring specialized tools, and is time-consuming, with the risk of omissions or incorrect installations. Second, uneven clamping occurs due to the rigid fixing method, resulting in uneven contact pressure distribution and a tendency for localized overload and overheating. Third, poor current sharing performance is caused by inconsistent impedances in each branch, leading to uneven current distribution and frequent issues such as current deviation and burn-out. Fourth, thermal deformation and loose connections are prone to occur; under high current operation, the metal components heat up, expand, and warp, causing a drop in contact pressure and creating a vicious cycle of loose connections. Fifth, maintenance is difficult; damaged components require complete disassembly, resulting in long downtime and high maintenance costs. Current technology lacks a systematic solution that can simultaneously achieve rapid assembly, stable contact, adaptive compensation for thermal deformation, and current sharing and temperature control, leading to high failure rates, short service lives, and cumbersome maintenance procedures for high-current contact components, failing to meet the requirements for long-term stable operation of heavy-duty automated equipment.

[0004] Therefore, a combined method for quick-connection of high-current contact components and a method for preventing loosening and stabilizing contacts are proposed to solve the problems mentioned above. Summary of the Invention

[0005] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a combined high-current contact quick-assembly and contact anti-loosening and stabilization method, which solves the problems of complex assembly, uneven clamping, poor current equalization, thermal deformation and poor connection, and difficult maintenance of existing 200A high-current contact components.

[0006] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a quick-assembly modular high-current contact component, comprising an insulating base, and further comprising a modular conductive contact unit mounted on the insulating base 1, a radial spring mechanism, an equal-resistance current-equalizing copper busbar, a contact consistency calibration structure, and a mistake-proof and error-proof assembly structure; the modular conductive contact unit is a dual-contact parallel structure used to carry a 200A current; the radial spring mechanism cooperates with the modular conductive contact unit to provide constant contact pressure and compensate for thermal deformation; the equal-resistance current-equalizing copper busbar is a symmetrical, equal-length, low-resistance structure, electrically connected to the modular conductive contact unit to achieve balanced current distribution; the contact consistency calibration structure is used to unify the height, contact pressure, and contact resistance of the modular conductive contact unit; the mistake-proof and error-proof assembly structure is an asymmetrical positioning structure located at the assembly point of the insulating base and the modular conductive contact unit.

[0007] Preferably, the insulating base is made of high-strength flame-retardant insulating material, which has high insulation performance and high creepage distance, and is used to support and isolate each conductive component.

[0008] Preferably, the radial spring mechanism incorporates a constant force spring assembly, which can maintain a stable contact force of the combined conductive contact unit under conditions of equipment vibration, contact wear, or high current heating, and can adaptively compensate for metal warping deformation.

[0009] Preferably, the combined conductive contact unit adopts a modular split design, and each contact component can be disassembled and replaced independently, while the insulating base and other undamaged parts can be reused.

[0010] Preferably, the equal resistance current-sharing copper busbar adopts a symmetrical and equal length structure design, and the impedance difference of each branch is controlled within 5%, ensuring that the 200A current is evenly distributed to the dual contacts.

[0011] Preferably, the contact consistency calibration structure includes a height adjustment component and a pressure calibration component, which can respectively adjust the installation height and contact pressure of the combined conductive contact unit, so that the height error of all contacts is ≤0.1mm and the contact resistance difference is ≤10mΩ.

[0012] Preferably, the error-proof and mis-assembly-proof structure includes an asymmetrical positioning boss and a corresponding groove. The boss is located on the insulating base, and the groove is located on the combined conductive contact unit. Assembly can only be completed in one direction to prevent reverse connection and short circuit.

[0013] Preferably, the combined conductive contact unit, radial spring mechanism, equal resistance current-equalizing copper busbar, contact consistency calibration structure, and foolproof assembly structure are all modular quick-release structures, and can be replaced individually without disassembling the entire machine when a single module is damaged.

[0014] Preferably, the constant force output range of the radial spring mechanism covers the contact wear amount of 0-2mm and the thermal deformation warping amount of 0-1mm, and the contact pressure fluctuation does not exceed ±5%, thus maintaining stable electrical contact over a long period of time.

[0015] A method for stabilizing and preventing loosening of combined high-current contact components further includes the following steps: Step 1: Using the asymmetrical bosses and grooves of the foolproof and error-proof assembly structure, align the combined conductive contact unit with the unique assembly direction of the insulating base to complete precise alignment; Step 2: Push the aligned combined conductive contact unit into the insulating base along the guide groove, and achieve quick locking without tools or screws through the buckle. The radial spring mechanism applies preload force simultaneously. Step 3: Adjust the height and pressure of each contact point through the contact consistency calibration structure to unify the height, pressure, and resistance parameters of all contacts; Step 4: During operation, the radial spring mechanism outputs a constant force to press the contacts, which compensates for the thermal deformation caused by the large current in real time. Together with the equal resistance current-equalizing copper busbar, it achieves a balanced distribution of 200A current and avoids current imbalance, overheating and loose connection. Step 5: After power off and cooling down, press the unlocking buckle of the insulating base to overcome the preload of the radial spring mechanism, pull out the damaged single contact module horizontally, install the new module and lock it. After local calibration, it can be used again.

[0016] (III) Beneficial Effects Compared with the prior art, the present invention provides a combined high-current contact quick-installation and contact anti-loosening and stabilization method, which has the following beneficial effects: 1. This modular high-current contact quick-assembly system utilizes an insulating base and a foolproof and error-proof assembly structure. The entire assembly is made of high-strength, flame-retardant insulating material in one piece, ensuring structural stability, reliable insulation, and sufficient creepage distance. It can support and isolate all conductive components, preventing leakage and short-circuit risks. Standardized mounting slots are pre-reserved on the base, providing precise positioning references for each component and ensuring assembly consistency. It also possesses vibration and aging resistance capabilities, adapting to the long-term operating conditions of heavy-duty AGVs and AMRs, significantly improving overall safety and service life.

[0017] 2. This modular high-current contact component features quick assembly, utilizing a modular conductive contact unit with a dual-contact parallel structure to meet the 200A high-current carrying capacity requirement. It boasts ample conductive cross-section, large contact area, low temperature rise, and reliable conductivity. The contacts adopt a modular, split design, supporting independent disassembly and replacement of individual contacts without requiring overall disassembly. The base is reusable, significantly reducing maintenance costs and shortening downtime. Its compact structure and strong interchangeability make it suitable for rapid assembly and on-site emergency replacement.

[0018] 3. This modular high-current contact quick-release mechanism utilizes a radial spring mechanism with a built-in constant force spring assembly to provide constant contact pressure. It adaptively compensates for vibration, wear, and high-current heating warping conditions, resulting in minimal contact pressure fluctuations and effectively preventing loose connections, arcing, and disconnections. It can simultaneously absorb contact wear and thermal deformation, maintaining tight contact over the long term and ensuring conductive stability. This fundamentally solves the problems of uneven pressure, thermal deformation, and easy loosening of contacts associated with traditional rigid fixing mechanisms. Attached Figure Description

[0019] Figure 1 This is a front view schematic diagram of a combined high-current contact quick-connect structure proposed in this invention; Figure 2 This is a side view schematic diagram of a combined high-current contact quick-installation structure proposed in this invention; Figure 3 This is a front view schematic diagram of a quick-assembly combined conductive contact unit for a combined high-current contact element proposed in this invention. Figure 4 This is a front view schematic diagram of a combined high-current contact quick-connect insulating base proposed in this invention.

[0020] In the diagram: 1. Insulating base; 2. Combined conductive contact unit; 3. Radial spring mechanism; 4. Equal resistance current equalization copper busbar; 5. Contact consistency calibration structure; 6. Mistake-proof and error-proof assembly structure. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figure 1-4 As shown, a quick-assembly modular high-current contact component includes an insulating base 1, a modular conductive contact unit 2 mounted on the insulating base 1, a radial spring mechanism 3, a current-equalizing copper busbar 4, a contact consistency calibration structure 5, and a foolproof and error-proof assembly structure 6. The modular conductive contact unit 2 is a dual-contact parallel structure used to carry a 200A current. The radial spring mechanism 3 cooperates with the modular conductive contact unit 2 to provide constant contact pressure and compensate for thermal deformation. The current-equalizing copper busbar 4 is a symmetrical, equal-length, low-resistance structure that is electrically connected to the modular conductive contact unit 2 to achieve balanced current distribution. The contact consistency calibration structure 5 is used to unify the height, contact pressure, and contact resistance of the modular conductive contact unit 2. The foolproof and error-proof assembly structure 6 is an asymmetrical positioning structure located at the assembly point between the insulating base 1 and the modular conductive contact unit 2.

[0023] First, the insulating base 1 is made of high-strength flame-retardant insulating material, which has high insulation performance and high creepage distance. It is used to support and isolate each conductive component. Through the structural strength and flame-retardant insulation characteristics of the integrally formed insulating base 1, it provides a stable mounting base for the combined conductive contact unit 2, radial spring mechanism 3, equal resistance current equalization copper busbar 4, contact consistency calibration structure 5, and foolproof and error-proof assembly structure 6. It effectively isolates the live parts, prevents leakage and creepage breakdown, and ensures electrical safety and structural stability under 200A high current conditions.

[0024] Secondly, the radial spring mechanism 3 has a built-in constant force spring assembly, which can maintain a stable contact force of the combined conductive contact unit 2 under conditions of equipment vibration, contact wear, or high current heating. It can also adaptively compensate for metal warping deformation. Through the elastic expansion and contraction characteristics of the constant force spring inside the radial spring mechanism 3, a constant clamping force is continuously applied to the combined conductive contact unit 2. It automatically compensates for displacement when the AGV is vibrating, the contacts are worn for a long time, or warps due to high current heating, thus avoiding loose contact, poor connection and arcing, and ensuring long-term reliable conductive connection.

[0025] Furthermore, the combined conductive contact unit 2 adopts a modular split design, and each contact component can be disassembled and replaced independently. The insulating base 1 and other undamaged parts can be reused. Through the split modular structure design of the combined conductive contact unit 2, the contact components can be independently assembled with the base, spring, and copper busbar. When damaged, only the corresponding contact module needs to be replaced. The insulating base 1, radial spring mechanism 3, and equal resistance current-equalizing copper busbar 4 do not need to be disassembled and reused, which greatly reduces maintenance costs and shortens downtime.

[0026] Furthermore, the equal resistance current sharing copper busbar 4 adopts a symmetrical and equal length structure design, and the impedance difference of each branch is controlled within 5%, ensuring that the 200A current is evenly distributed to the two contacts. Through the symmetrical and equal length, same material and cross-section of the equal resistance current sharing copper busbar 4, the consistency of branch impedance is strictly controlled, so that the 200A current is evenly distributed between the two sets of contacts, avoiding single contact overload and current deviation erosion, reducing the temperature rise of the contact, and improving the conductivity reliability and service life.

[0027] Furthermore, the contact consistency calibration structure 5 includes a height adjustment component and a pressure calibration component, which can adjust the installation height and contact pressure of the combined conductive contact unit 2 respectively, so that the height error of all contacts is ≤0.1mm and the contact resistance difference is ≤10mΩ. Through the height adjustment component and pressure calibration shim of the contact consistency calibration structure 5, the installation position of the combined conductive contact unit 2 and the preload of the radial spring mechanism 3 are precisely adjusted, the height, clamping force and contact resistance of each contact are unified, assembly deviations are eliminated, multi-contact synchronous and stable conduction is guaranteed, and the consistency of batch products is improved.

[0028] Furthermore, the foolproof and error-proof assembly structure 6 includes an asymmetrical positioning boss and a corresponding groove. The boss is set on the insulating base 1, and the groove is set on the combined conductive contact unit 2. Assembly can only be completed in one direction to prevent reverse connection and short circuit. By the cooperation of the asymmetrical boss on the insulating base 1 and the irregular groove on the combined conductive contact unit 2, a unique assembly path is formed. When reversed or misaligned, it cannot be locked, forcing correct alignment and avoiding reverse polarity connection and short circuit caused by human error in assembly, thus improving assembly efficiency and safety.

[0029] Furthermore, the combined conductive contact unit 2, radial spring mechanism 3, equal resistance current equalization copper busbar 4, contact consistency calibration structure 5, and foolproof and error-proof assembly structure 6 are all modular quick-release structures. When a single module is damaged, it can be replaced individually without disassembling the entire machine. Through the modular quick-release design of the entire assembly, each functional component is independently molded and snap-fit ​​assembled. When any module fails, it can be directly unlocked and pulled out for replacement. The insulating base 1 is retained as a whole. There is no need to disassemble the whole machine or other intact parts, which significantly simplifies the maintenance process and reduces downtime.

[0030] Finally, the constant force output range of the radial spring mechanism 3 covers the contact wear amount of 0-2mm and the thermal deformation warping amount of 0-1mm, with the contact pressure fluctuation not exceeding ±5%, maintaining stable electrical contact over a long period of time. Through the stroke design of the constant force spring of the radial spring mechanism 3, it can absorb 0-2mm contact wear and 0-1mm thermal warping deformation, keeping the contact pressure fluctuation ≤±5% throughout the process, avoiding pressure decay leading to poor connection and increased contact resistance, and maintaining stable conductive connection quality during long-term operation.

[0031] A method for stabilizing and preventing loosening of combined high-current contact components further includes the following steps: Step 1: Using the asymmetrical bosses and grooves of the foolproof and error-proof assembly structure 6, align the combined conductive contact unit 2 with the unique assembly direction of the insulating base 1 to complete precise alignment; Step 2: Push the aligned combined conductive contact unit 2 into the insulating base 1 along the guide groove, and achieve quick locking without tools or screws through the buckle. The radial spring mechanism 3 applies preload force simultaneously. Step 3: Adjust the height and pressure of each contact point using the contact consistency calibration structure 5 to ensure that the height, pressure, and resistance parameters of all contacts are uniform; Step 4: During operation, the radial spring mechanism 3 outputs a constant force to press the contacts, which compensates for the thermal deformation caused by the large current in real time. Together with the equal resistance current equalization guide copper busbar 4, it achieves a balanced distribution of 200A current and avoids current imbalance, overheating and loose connection. Step 5: After power off and cooling down, press the insulating base 1 to unlock the buckle, overcome the pre-tightening force of the radial spring mechanism 3, pull out the damaged single contact module horizontally, install the new module and lock it. After local calibration, it can be used again.

[0032] Working principle: The present invention provides a combined high-current contact quick assembly and contact anti-loosening and stabilization method. Its overall working principle relies on the coordinated cooperation of an insulating base 1, a combined conductive contact unit 2, a radial spring mechanism 3, an equal resistance current equalization and guiding copper busbar 4, a contact consistency calibration structure 5, and a foolproof and error-proof assembly structure 6 to achieve six core functions: rapid assembly, constant force anti-loosening, current equalization and temperature control, thermal deformation compensation, consistency stabilization, and reverse assembly safety.

[0033] First, during the assembly stage, the unique orientation is achieved by relying on the foolproof and error-proof assembly structure 6. The asymmetrical boss on the insulating base 1 precisely engages with the asymmetrical groove on the combined conductive contact unit 2, preventing reverse connection, incorrect assembly, and short circuit, ensuring a unique assembly orientation and eliminating human error. Then, the combined conductive contact unit 2 is pushed into the guide groove of the insulating base 1 and quickly locked by the snap-fit, completing the quick assembly without screws or tools. The radial spring mechanism 3 is pre-compressed during the pushing process, automatically providing constant contact pressure, keeping the combined conductive contact unit 2 in an elastic floating state.

[0034] Secondly, during the consistency calibration stage, the height and pressure of the combined conductive contact unit 2 are adjusted by the contact consistency calibration structure 5. The height adjustment component ensures that all contact points are at the same height, and the preload of the radial spring mechanism 3 is finely adjusted by the pressure calibration shim. Ultimately, this ensures that the height, pressure, and contact resistance of all contact points are uniform, avoiding uneven contact force and inconsistent conductivity caused by dimensional deviations.

[0035] During normal operation, the dual contacts of the combined conductive contact unit 2 carry a 200A current in parallel, with the current evenly distributed thanks to the equal-resistance current-sharing copper busbar 4. The equal-resistance current-sharing copper busbar 4 has a symmetrical, equal-length, low-resistance structure, with consistent impedance in both branches, ensuring uniform current distribution and preventing current imbalance, localized overheating, and erosion. Simultaneously, the radial spring mechanism 3 continuously outputs a constant force to press the combined conductive contact unit 2. When the equipment vibrates, the contacts wear, or warp due to high current heating, the spring automatically extends and retracts to compensate for contact wear and thermal deformation, maintaining stable contact pressure and preventing loose connections, arcing, and forming an adaptive stabilization mechanism for thermal deformation.

[0036] During maintenance and replacement, the pre-tightening force of the radial spring mechanism 3 is released by the unlocking buckle on the side of the insulating base 1, allowing a single damaged combined conductive contact unit 2 to be horizontally pulled out for independent quick replacement. The insulating base 1, radial spring mechanism 3, equal resistance current equalization and guiding copper busbar 4, contact consistency calibration structure 5, and foolproof and error-proof assembly structure 6 are all reusable, making maintenance convenient, requiring no disassembly, with short downtime and low cost. In summary, this invention solves the defects of existing technologies through the synergistic work of the above structures, from assembly, conductivity, clamping, current equalization, compensation, and maintenance, achieving rapid assembly of 200A high-current contact components, long-term stable conductivity, prevention of loosening and poor connection, and low-cost maintenance, meeting the long-term reliable operation requirements of heavy-duty AGV and AMR automated equipment.

[0037] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A quick-connect composite high-current contact element, comprising an insulating base (1), characterized in that: It also includes a combined conductive contact unit (2), a radial spring mechanism (3), an equal resistance current-equalizing copper busbar (4), a contact consistency calibration structure (5), and a foolproof and error-proof assembly structure (6) installed on an insulating base (1); the combined conductive contact unit (2) is a double-contact parallel structure used to carry 200A current; the radial spring mechanism (3) cooperates with the combined conductive contact unit (2) to provide constant contact pressure and compensate for thermal deformation; the equal resistance current-equalizing copper busbar (4) is a symmetrical, equal-length, low-resistance structure, which is electrically connected to the combined conductive contact unit (2) to achieve balanced current distribution; the contact consistency calibration structure (5) is used to unify the height, contact pressure, and contact resistance of the combined conductive contact unit (2); the foolproof and error-proof assembly structure (6) is an asymmetrical positioning structure located at the assembly point of the insulating base (1) and the combined conductive contact unit (2).

2. The quick-connect combination high-current contact element according to claim 1, characterized in that: The insulating base (1) is made of high-strength flame-retardant insulating material, which has high insulation performance and high creepage distance, and is used to support and isolate each conductive component.

3. The quick-connect combination high-current contact element according to claim 1, characterized in that: The radial spring mechanism (3) has a built-in constant force spring assembly, which can maintain the stable contact force of the combined conductive contact unit (2) under conditions of equipment vibration, contact wear or high current heating, and can adaptively compensate for metal warping deformation.

4. The quick-connect combination high-current contact element according to claim 1, characterized in that: The combined conductive contact unit (2) adopts a modular split design, and each contact component can be disassembled and replaced independently. The insulating base (1) and other undamaged parts can be reused.

5. A quick-connect combination high-current contact element according to claim 1, characterized in that: The equal resistance current equalization copper busbar (4) adopts a symmetrical equal length structure design, and the impedance difference of each branch is controlled within 5%, so as to ensure that the 200A current is evenly distributed to the double contacts.

6. A quick-connect combination high-current contact element according to claim 1, characterized in that: The contact consistency calibration structure (5) includes a height adjustment component and a pressure calibration component, which can respectively adjust the installation height and contact pressure of the combined conductive contact unit (2) so that the height error of all contacts is ≤0.1mm and the contact resistance difference is ≤10mΩ.

7. A quick-connect combination high-current contact element according to claim 1, characterized in that: The error-proof assembly structure (6) includes an asymmetrical positioning boss and a corresponding groove. The boss is set on the insulating base (1), and the groove is set on the combined conductive contact unit (2). Assembly can only be completed in one direction to prevent reverse connection and short circuit.

8. A quick-connect combination high-current contact element according to claim 1, characterized in that: The combined conductive contact unit (2), radial spring mechanism (3), equal resistance current equalization guide copper busbar (4), contact consistency calibration structure (5) and foolproof and error-proof assembly structure (6) are all modular quick-release structures, and can be replaced individually without disassembling the whole machine when a single module is damaged.

9. A quick-connect combination high-current contact element according to claim 1, characterized in that: The constant force output range of the radial spring mechanism (3) covers the contact wear amount of 0-2mm and the thermal deformation warping amount of 0-1mm, and the contact pressure fluctuation does not exceed ±5%, thus maintaining stable electrical contact over a long period of time.

10. A method for preventing loosening and stabilizing the contact of a combined high-current contact, applied to a quick-connect method for a combined high-current contact as described in any one of claims 1-9, characterized in that, It also includes the following steps: Step 1: Using the asymmetrical bosses and grooves of the foolproof and error-proof assembly structure (6), align the combined conductive contact unit (2) with the unique assembly direction of the insulating base (1) to complete the precise alignment; Step 2: Push the aligned combined conductive contact unit (2) into the insulating base (1) along the guide groove, and achieve quick locking without tools or screws through the buckle. The radial spring mechanism (3) applies pre-tightening force simultaneously. Step 3: Adjust the height and pressure of each contact point through the contact consistency calibration structure (5) to make the height, pressure and resistance parameters of all contacts uniform; Step 4: During operation, the radial spring mechanism (3) outputs constant force to press the contacts, which compensates for the thermal deformation caused by the large current in real time. It works with the equal resistance current equalization guide copper bus (4) to achieve a balanced distribution of 200A current and avoid bias, overheating and loose connection. Step 5: After power off and cooling down, press the insulating base (1) to unlock the buckle, overcome the pre-tightening force of the radial spring mechanism (3), pull out the damaged single contact module horizontally, install the new module and lock it. After local calibration, it can be used again.

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