Actuated Electrical Contact Unit for High-Current Connections
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Solution Overview
Problem
Existing contact connector systems face limitations in handling high charging currents due to physical constraints, such as limited contact area and human-handling difficulties, which hinder the development of fast-charging capabilities for battery storage systems.
Innovation Solution
An electrical contact unit with movable connecting parts and a positioning unit, actuator, and locking mechanism, utilizing elastic prestressing elements, magnets, and sensors to ensure secure and efficient high-current connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact area of electrical contacts is increased to reduce contact resistance, then the electrical connection quality is improved, but the component dimensions become difficult for human handling
Solution Approach 1:
The first connecting part is divided into a first section and a second section, with the second section being movable relative to the first section. This segmentation allows the electrical contact (on the second section) to be displaced to achieve proper contact alignment without requiring the entire component to be large, thus maintaining both good electrical connection and human handling capability.
Solution Approach 2:
The second section is designed to be movable relative to the first section along the contacting axis. This dynamic capability allows the electrical contact to be positioned correctly during the connecting process, enabling sufficient contact area and force while keeping the overall component size manageable for human operation.
2Reliability
If the contact force between electrical contacts is increased to reduce contact resistance, then the electrical connection quality is improved, but the natural limit of human capability is reached
Solution Approach 1:
The movable second section enables dynamic adjustment of contact force during the connecting process. The actuator can apply additional force beyond what human operators can naturally provide, ensuring sufficiently high contact force and low contact resistance while keeping the initial assembly process within human capability limits.
Solution Approach 2:
An actuator is introduced to replace or supplement human mechanical force application. The actuator can precisely control and apply the necessary contact force between electrical contacts, overcoming the natural limits of human capability while ensuring reliable electrical connection.
3Productivity
If the charging current is increased to achieve fast charging, then the charging rate is improved, but the requirements for contact connector system quality increase
Solution Approach 1:
The movable second section allows the system to dynamically adjust to the high current conditions. By ensuring precise alignment and sufficient contact force through the movable mechanism, the electrical connection maintains high quality even when transmitting very high charging currents required for fast charging applications.
Solution Approach 2:
The actuator replaces manual force application with a controlled mechanical system that can consistently provide the necessary contact force for high-current transmission. This ensures reliable electrical connection quality under the demanding conditions of fast charging with high charging currents.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-power electrical connections with secure contact forces, efficient space utilization, and safety features, allowing for rapid charging of battery storage systems.
Implementation Method 1
The connection can be realized in the first and/or second electrical contact with an elastic prestressing element, for example a mechanical spring, so that the two contacts, when they lie against each other, can touch each other with a prestressing force.
Implementation Method 2
The contact unit can have a locking element; wherein the locking element is movable between a locking position and an unlocking position; and wherein the locking element prevents movement of the first portion of the first connecting part relative to the second connecting part in the locking position
Implementation Method 3
an actuator which, when the first section of the first connecting part is in the rest position, is designed to displace the second section of the first connecting part in the contacting direction relative to the first section such that the second section of the first connecting part and the second connecting part lie against one another in the contacting direction and the first electrical contact and the second electrical contact touch one another
Data Source
Figure 1
Figure 2(a)~2(d)
Figure 3(a)~3(f)
AI summary
The invention relates to a contact unit (1) for establishing an electrically conductive connection, comprising a first connection part (100) with a first electric contact (121) and a second connection part (200) with a second electric contact (221), wherein the first connection part (100) comprises a first section (101) and a second section (102); the first connection part (100) can be positioned in a rest position along a contacting axis (11) relative to the second connection part (200); the first electric contact (121) and the second electric contact (221) are designed to produce an electrically conductive connection between the first connection part (100) and the second connection part (200) upon contact, said electrically conductive connection being designed to conduct electric energy; and the contact unit (1) additionally comprises a positioning unit (131, 110, 210) for a rest position. The contact unit also comprises an actuator (140) which is designed to move the second section (102) of the first connection part (100) in the contacting direction (12) relative to the first section (101).