Soft connection structure based on inductance monitoring and connector

Abstract

The utility model relates to the technical field of electric connection, especially a soft connection structure and connector based on inductance monitoring, including fixed sleeve, plug -in terminal, soft connection element, electricity -connection element, inductive element and inductive connection subassembly, fixed sleeve is provided with terminal fixed cavity and electricity -connection fixed cavity, plug -in terminal sets up in terminal fixed cavity, electricity -connection element sets up in electricity -connection fixed cavity, both ends of soft connection element are connected plug -in terminal and electricity -connection element respectively, inductive element is annular inductance, its setting is in the outside of electricity -connection fixed cavity, inductive connection subassembly and inductive element electric connection. The utility model utilizes the principle that the inductance magnetic field changes due to current change, can sensitively capture the tiny arc current signal caused by bad contact, abnormal heating or insulation deterioration, realizes the early warning to potential arc fault, improves the fire safety level of photovoltaic system.

Description

Technical Field

[0001] This utility model relates to the field of electrical connection technology, and in particular to a soft connection structure and connector based on inductance monitoring. Background Technology

[0002] As a critical electrical interface in photovoltaic power generation systems, the long-term reliability and safety of photovoltaic connectors directly impact the power generation efficiency and stability of the entire power station. Under complex outdoor conditions, traditional photovoltaic connectors commonly face problems such as increased contact resistance, localized overheating, and even arcing due to vibration, temperature cycling, and contact oxidation. In severe cases, this can lead to open flame accidents and significant losses. To address these challenges, existing technologies primarily focus on optimizing the connector's mechanical locking structure, improving sealing performance, or using contact materials with higher conductivity. While these methods enhance the reliability of the physical connection to some extent, they lack real-time, online monitoring capabilities for the electrical connection status, making it difficult to provide timely warnings of potential faults.

[0003] Currently, some improvement solutions attempt to introduce external current transformers or temperature sensors for status monitoring, but these solutions typically suffer from complex structures, inconvenient installation, and high costs. External sensors often require additional wiring, increasing system complexity and failure risks; the additional contact points they introduce can also become new heat sources. Furthermore, while using series sampling resistors can detect current, it introduces additional power losses, reduces system efficiency, and the resistors themselves are prone to heating, potentially exacerbating localized temperature rises in high-temperature environments. Therefore, achieving non-contact, multi-parameter intelligent monitoring within a compact connector structure without interrupting load or introducing additional power consumption has become a crucial direction for the upgrading of photovoltaic connector technology. The industry urgently needs a new connector structure solution that integrates current monitoring, arc detection, and temperature inversion functions without sacrificing original electrical performance and mechanical strength. Utility Model Content

[0004] To address the aforementioned issues, this invention directly senses changes in current flowing through the flexible connector and the connecting element, enabling precise measurement and monitoring of branch current. Utilizing the principle that changes in current lead to changes in the inductive magnetic field, it can sensitively capture minute arcing current signals caused by poor contact, abnormal heating, or insulation degradation, achieving early warning of potential arcing faults. This significantly improves the fire safety level of photovoltaic systems through its inductively monitored flexible connector structure and connector.

[0005] The technical solution adopted by this utility model is: a flexible connection structure based on inductance monitoring, including a fixed sleeve, a plug-in terminal, a flexible connection element, a power-connecting element, an inductor element, and an inductance connection assembly. The fixed sleeve is provided with a terminal fixing cavity and a power-connecting fixing cavity. The plug-in terminal is disposed in the terminal fixing cavity, and the power-connecting element is disposed in the power-connecting fixing cavity. The two ends of the flexible connection element are respectively connected to the plug-in terminal and the power-connecting element. The inductor element is a ring inductor, which is disposed outside the power-connecting fixing cavity. The inductance connection assembly is electrically connected to the inductor element.

[0006] A further improvement to the above scheme is that one end of the fixed sleeve is provided with a fixed end, the power-connecting fixed cavity is provided at the fixed end, and multiple fixed plates extend rearward from the end of the fixed end, the fixed plates being used to fix the power-connecting components.

[0007] A further improvement to the above scheme is that four fixing plates are provided, the four fixing plates are arranged in a rectangular shape and form a fixing through groove, and the power connection element is arranged in the fixing through groove.

[0008] A further improvement to the above solution is that two adjacent fixing plates are not connected to each other.

[0009] A further improvement to the above solution is that the upper and lower fixing plates are provided with fixing buckles opposite each other, and the power receiving element is provided with a fixing slot, and the power receiving element is engaged with the fixing buckle through the fixing slot.

[0010] A further improvement to the above scheme is that through slots are provided on the left and right fixing plates, and the through slots are used to connect the inductor and the power supply.

[0011] A further improvement to the above solution is that the flexible connection element is formed by interlacing multiple copper wires, and both ends of the flexible connection element are connected to the plug-in terminal and the electrical connection element by hot-melt welding.

[0012] A further improvement to the above scheme is that at least two inductor elements are provided, and the at least two inductor elements are arranged continuously along the axial direction of the flexible connection element; the inductor element includes a C-shaped magnetic core and a coil, and the coil is wound around the outside of the magnetic core and is opposite to the flexible connection element in at least three directions.

[0013] A further improvement to the above solution is that the inductor connection assembly includes a circuit board and power terminals, the power terminals are disposed on the circuit board, and the inductor element is connected to the power terminals through the circuit board.

[0014] A connector comprising the aforementioned inductance-monitored flexible connection structure.

[0015] The beneficial effects of this utility model are: Compared to existing connector monitoring systems, this invention integrates a ring-shaped inductor into the flexible connection structure, achieving multi-dimensional real-time intelligent monitoring of the photovoltaic connector's operating status, resulting in significant technological advancements and beneficial effects. Specifically, the ring-shaped inductor is non-contactly fitted outside the connection fixing cavity, directly sensing current changes flowing through the flexible connection element and the connection element, enabling precise measurement and monitoring of branch currents. Utilizing the principle that current changes lead to changes in the inductor's magnetic field, it can sensitively capture minute arcing current signals caused by poor contact, abnormal heating, or insulation degradation, providing early warning of potential arcing faults and greatly improving the fire safety level of the photovoltaic system. Simultaneously, the inductor monitors the abnormal temperature rise trend caused by overload or increased contact resistance, achieving non-contact indirect temperature monitoring, avoiding the limitations and reliability issues of traditional temperature sensors that require direct placement. Seamlessly embedding the monitoring function into the existing connection structure eliminates the need for conductor cutting or series sampling resistors, avoiding additional power consumption and hotspot generation, ensuring that the original current-carrying capacity and electrical performance remain unaffected. The flexible connection element effectively absorbs and compensates for displacement caused by vibration and thermal stress, maintaining connection stability. The integrated design of the fixed sleeve organically combines the terminal fixing cavity and the power connection fixing cavity, resulting in a compact structure that facilitates installation and maintenance. The external arrangement of the ring-shaped inductor not only avoids direct contact with high-voltage conductors, improving insulation reliability, but also simplifies the assembly process and reduces production costs. The overall structure exhibits excellent environmental adaptability, making it suitable for harsh conditions in outdoor photovoltaic power stations, such as high humidity and large temperature differences. This invention achieves a unified approach to intelligent monitoring and high-reliability connection, significantly improving the operating efficiency, safety level, and maintenance convenience of photovoltaic systems, and has broad application prospects. Attached Figure Description

[0016] Figure 1 This is a three-dimensional schematic diagram of the soft connection structure based on inductor monitoring of this utility model; Figure 2 for Figure 1 An exploded view of a soft connection structure based on inductor monitoring in China; Figure 3 for Figure 1 An exploded view of the soft connection structure based on inductor monitoring from another perspective; Figure 4 for Figure 1 A partial structural diagram of the soft connection structure based on inductor monitoring.

[0017] Explanation of reference numerals in the attached drawings: 1. Fixing sleeve; 11. Terminal fixing cavity; 12. Power connection fixing cavity; 13. Fixing end; 14. Fixing plate; 141. Fixing buckle; 142. Through groove; 2. Plug-in terminal; 3. Flexible connection element; 4. Power connection element; 41. Fixing slot; 5. Inductor element; 51. Magnetic core; 52. Coil; 6. Inductor connection assembly; 61. Circuit board; 62. Power connection terminal. Detailed Implementation

[0018] To facilitate understanding of this utility model, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of this utility model are shown in the drawings. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this utility model.

[0019] It should be noted that when a component is said to be "fixed to" another component, it can be directly attached to the other component or there may be an intervening component. When a component is said to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component.

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Figures 1-4As shown, in one embodiment of this utility model, a flexible connection structure based on inductor monitoring is disclosed, including a fixed sleeve 1, a plug-in terminal 2, a flexible connection element 3, a power-connecting element 4, an inductor element 5, and an inductor connection assembly 6. The fixed sleeve 1 is provided with a terminal fixing cavity 11 and a power-connecting fixing cavity 12. The plug-in terminal 2 is disposed in the terminal fixing cavity 11, and the power-connecting element 4 is disposed in the power-connecting fixing cavity 12. The two ends of the flexible connection element 3 are respectively connected to the plug-in terminal 2 and the power-connecting element 4. The inductor element 5 is a ring-shaped inductor, which is disposed outside the power-connecting fixing cavity 12. The inductor connection assembly 6 is electrically connected to the inductor element 5. This embodiment, by integrating the ring-shaped inductor element 5 into the flexible connection structure, realizes multi-dimensional real-time intelligent monitoring of the photovoltaic connector's operating status, bringing significant technological progress and beneficial effects. Specifically, the ring-shaped inductor is non-contactly sleeved outside the power-connecting fixing cavity 12, and can directly sense the current changes flowing through the flexible connection element 3 and the power-connecting element 4, realizing accurate measurement and monitoring of the branch current. Utilizing the principle that changes in current lead to changes in the inductor's magnetic field, this system can sensitively capture minute arcing current signals caused by poor contact, abnormal heating, or insulation degradation, enabling early warning of potential arcing faults and significantly improving the fire safety level of photovoltaic systems. Simultaneously, inductor element 5 monitors the abnormal temperature rise trend caused by overload or increased contact resistance, achieving non-contact indirect temperature monitoring, avoiding the limitations and reliability issues of traditional temperature sensors that require direct placement. Seamlessly embedding the monitoring function into the existing connection structure eliminates the need for conductor cutting or series sampling resistors, avoiding additional power consumption and hotspot generation, and ensuring that the original current-carrying capacity and electrical performance remain unaffected. Flexible connection element 3 effectively absorbs and compensates for displacement caused by vibration and thermal stress, maintaining connection stability. The integrated design of the fixed sleeve 1 organically combines the terminal fixing cavity 11 and the power connection fixing cavity 12, resulting in a compact structure that facilitates installation and maintenance. The external arrangement of the ring-shaped inductor not only avoids direct contact with high-voltage conductors, improving insulation reliability, but also simplifies the assembly process and reduces production costs. The overall structure exhibits excellent environmental adaptability, making it suitable for harsh operating conditions in outdoor photovoltaic power stations, such as high humidity and large temperature differences. This embodiment achieves a unified approach to intelligent monitoring and highly reliable connectivity, significantly improving the operating efficiency, safety level, and maintenance convenience of the photovoltaic system, and has broad application prospects.

[0021] One end of the fixed sleeve 1 is provided with a fixed end 13, and the power-connecting fixed cavity 12 is located at the fixed end 13. Multiple fixed plates 14 extend rearward from the end of the fixed end 13, and the fixed plates 14 are used to fix the power-connecting element 4. In this embodiment, the multiple fixed plates 14 are arranged around the power-connecting fixed cavity 12, forming a rigid multi-point snap-fit ​​or clamping structure. When the power-connecting element 4 is placed into the power-connecting fixed cavity 12, the fixed plates 14 can form a stable surround and press it from the circumference. The multi-point fixing method greatly enhances the tensile strength and torsional resistance of the power-connecting element 4, effectively preventing it from loosening or shifting during long-term operation or due to external vibration or thermal expansion and contraction, thereby ensuring the long-term stability of the electrical connection interface and avoiding safety hazards such as increased contact resistance and localized overheating caused by poor contact.

[0022] The two adjacent fixing plates 14 are not connected to each other. The upper and lower fixing plates 14 are provided with opposing fixing buckles 141, and the power receiving element 4 is provided with a fixing slot 41. The power receiving element 4 is engaged with the fixing buckle 141 through the fixing slot 41. In this embodiment, the independent design of the adjacent fixing plates 14 gives them a certain degree of elastic deformation capability. When installing the power receiving element 4, the fixing plates 14 can slightly open elastically, facilitating the smooth insertion of the power receiving element 4. The engaging structure formed by the upper and lower opposing fixing buckles 141 and the fixing slot 41 of the power receiving element 4 achieves rapid locking. This engaging mechanism not only facilitates assembly and greatly improves assembly efficiency, but also effectively prevents the power receiving element 4 from axial movement or loosening under vibration through a mechanical interlocking mechanism, ensuring the ultimate reliability of the connection. The engagement between the clip and the slot ensures a secure fixation while defining the only correct installation position for the power connection element 4, preventing poor contact caused by misalignment. This provides a guarantee for a stable electrical connection between the flexible connection element 3 and the power connection element 4, thereby ensuring the accuracy of the inductance monitoring data and the safety of the entire photovoltaic connector system.

[0023] The two fixing plates 14 on the left and right sides are provided with through slots 142, which are used to connect the inductor 5 and the power-connecting element 4. In this embodiment, by directly opening through slots 142 on the fixing plates 14, a direct and efficient electrical connection channel is established between the inductor 5 and the power-connecting element 4. This completely avoids the complexity of requiring additional wires in traditional structures, not only simplifying the internal wiring structure and reducing manufacturing costs, but more importantly, significantly shortening the current monitoring path and reducing line impedance and signal attenuation. The structural design of the through slots 142 allows the inductor 5 to sense current changes in the power-connecting element 4 with the shortest distance, thereby greatly improving the sensitivity and accuracy of current detection and providing a reliable data foundation for real-time monitoring of the soft connection's working status.

[0024] The flexible connector 3 is formed by interlacing multiple copper wires. Both ends of the flexible connector 3 are connected to the plug-in terminal 2 and the connecting element 4 by thermofusion welding. In this embodiment, the interlaced structure of the multiple copper wires gives the flexible connector 3 excellent flexibility and fatigue resistance, enabling it to effectively absorb stresses such as vibration and thermal expansion and contraction generated during equipment operation, avoiding metal fatigue fracture caused by rigid connections, and improving the durability and reliability of the connection structure. The end connection is achieved through thermofusion welding, which can form a metallurgical bond at the molecular level, resulting in extremely low interface resistance and extremely high stability. This completely eliminates the problems of contact loosening and resistance increase caused by oxidation that may occur with traditional bolt crimping, ensuring the high efficiency and stability of current transmission. The low-resistance connection combined with the flexibility of the flexible connector itself provides a stable and interference-free current sampling environment for the inductor element 5, ensuring the accuracy and authenticity of the monitoring data, thus providing a solid foundation for inductor-based flexible connector status monitoring.

[0025] At least two inductor elements 5 are provided, and the at least two inductor elements 5 are continuously arranged along the axial direction of the flexible connection element 3. Each inductor element 5 includes a C-shaped magnetic core 51 and a coil 52. The coil 52 is wound around the outside of the magnetic core 51 and is opposite to the flexible connection element 3 in at least three directions. In this embodiment, the continuous axial arrangement of at least two inductor elements 5 constitutes a multi-point sampling and signal redundancy mechanism. This enables segmented and multi-point sensing and monitoring of the current flowing through the flexible connection element 3, effectively avoiding misjudgments caused by abnormal data at a single monitoring point or local interference, and improving the overall reliability and data comprehensiveness of the monitoring system. The sensing unit composed of the C-shaped magnetic core 51 and the coil 52 wound around it, by being opposite to the flexible connection element 3 in at least three directions, greatly optimizes the magnetic circuit closure effect and enhances the magnetic field coupling efficiency, thereby ensuring high sensitivity detection of weak current changes. The multi-point, multi-dimensional sensing design can not only accurately capture the amplitude information of the current, but also help to analyze the dynamic characteristics and distribution uniformity of the current. This provides richer and more accurate diagnostic basis for assessing the connection status of the soft connection and warning of potential faults such as overload or poor contact, which greatly improves the intelligent monitoring level and operational safety of the entire photovoltaic connector system.

[0026] The inductor connection assembly 6 includes a circuit board 61 and a power terminal 62. The power terminal 62 is mounted on the circuit board 61, and the inductor element 5 is connected to the power terminal 62 via the circuit board 61. In this embodiment, the signal output terminal of the inductor element 5 is directly led to the circuit board 61 and connected to the power terminal 62 via onboard wiring, achieving a high degree of integration of signal acquisition, transmission, and output. This simplifies external wiring, avoids cumbersome flying wires or manual soldering, reduces assembly complexity and production costs, and ensures the consistency and stability of the signal path through standardized circuit board 61 wiring, effectively reducing measurement errors caused by loose connections or uneven line impedance. The circuit board 61 also provides a physical carrier for subsequent integration of signal conditioning circuits, data processing chips, or communication modules, expanding the space for realizing local signal preprocessing, digital conversion, and remote transmission functions, and improving the integration, anti-interference capability, and intelligence level of the entire current monitoring system.

[0027] The above embodiments only illustrate several implementation methods of this utility model, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A soft connection structure based on inductor monitoring, characterized in that: The device includes a fixed sleeve, plug-in terminals, flexible connecting elements, power-connecting elements, inductors, and an inductor connection assembly. The fixed sleeve has a terminal fixing cavity and a power-connecting fixing cavity. The plug-in terminals are located in the terminal fixing cavity, and the power-connecting elements are located in the power-connecting fixing cavity. The two ends of the flexible connecting elements are respectively connected to the plug-in terminals and the power-connecting elements. The inductor is a ring-shaped inductor and is located outside the power-connecting fixing cavity. The inductor connection assembly is electrically connected to the inductor.

2. The soft connection structure based on inductor monitoring according to claim 1, characterized in that: One end of the fixed sleeve is provided with a fixed end, the power-connecting fixed cavity is provided at the fixed end, and multiple fixing plates extend rearward from the end of the fixed end. The fixing plates are used to fix the power-connecting components.

3. The soft connection structure based on inductor monitoring according to claim 2, characterized in that: The fixing plate is provided in four rectangular arrangements, forming a fixing through groove, and the power connection element is disposed in the fixing through groove.

4. The soft connection structure based on inductor monitoring according to claim 3, characterized in that: The two adjacent fixing plates are not connected to each other.

5. The soft connection structure based on inductor monitoring according to claim 3, characterized in that: The upper and lower fixing plates are provided with fixing buckles opposite each other, and the power receiving element is provided with a fixing slot. The power receiving element is engaged with the fixing buckle through the fixing slot.

6. The soft connection structure based on inductor monitoring according to claim 5, characterized in that: The two fixed plates on the left and right sides are provided with through slots, which are used to connect the inductor and the power supply.

7. The soft connection structure based on inductor monitoring according to claim 1, characterized in that: The flexible connector is formed by interlacing multiple copper wires, and both ends of the flexible connector are connected to the plug-in terminal and the electrical connection element by hot-melt welding.

8. The soft connection structure based on inductor monitoring according to claim 1, characterized in that: At least two inductor elements are provided, and the at least two inductor elements are arranged continuously along the axial direction of the flexible connector element; the inductor element includes a C-shaped magnetic core and a coil, the coil being wound around the outside of the magnetic core and being opposite to the flexible connector element in at least three directions.

9. The soft connection structure based on inductor monitoring according to claim 1, characterized in that: The inductor connection assembly includes a circuit board and power terminals. The power terminals are disposed on the circuit board, and the inductor element is connected to the power terminals through the circuit board.

10. A connector, characterized in that: Includes the soft connection structure based on inductor monitoring as described in any one of claims 1 to 9.

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