Asymmetric High-Current Connector for Wind Turbines
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Solution Overview
Problem
Conventional high-current plug-in connectors for wind turbine generator systems face challenges in space-saving arrangement, meeting electrical requirements for high currents, and preventing accidental cabling due to insufficient space and complex coding systems.
Innovation Solution
Designing unipolar high-current plug-in connectors with a cross-section where the longitudinal extent exceeds the transverse extent, incorporating oval or non-square shapes, annular spring elements for reliable contact, and visible mechanical coding to prevent polarity reversal, allowing for efficient assembly and secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional plug-in connectors with sufficient cable cross-section and contact surface are used, then high current requirements are met, but radial dimensions become too large for space-saving arrangement
Solution Approach 1:
The patent applies asymmetry by designing the contact cross-section as non-circular (rectangular or oval) where the longitudinal extent exceeds the transverse extent. This asymmetric shape allows the contact to fit within a smaller radial envelope while maintaining sufficient cross-sectional area for high current capacity, directly resolving the contradiction between current-carrying capacity and radial dimensions.
2Reliability
If conventional coding systems are used to prevent incorrect cabling, then polarity reversal is prevented, but assembly complexity increases due to trial and error
Solution Approach 1:
The asymmetric cross-section shape itself serves as the coding mechanism. The plug and coupling have complementary asymmetric shapes that only fit together in the correct orientation, eliminating the need for separate coding elements. This reduces assembly complexity while maintaining polarity correctness, as the shape guide ensures proper alignment without trial and error.
Solution Approach 2:
The patent extracts the coding function from separate coding elements and integrates it directly into the contact shape itself. The asymmetric geometry of the contact serves dual purposes: electrical conduction and polarity identification, simplifying the overall assembly process while maintaining reliability.
3Adaptability or versatility
If multiple plug-in connectors are arranged beside one another, then all cable connections are provided, but space requirements exceed available tower space
Solution Approach 1:
The asymmetric contact shape with longitudinal extent exceeding transverse extent allows multiple connectors to be arranged in a compact configuration. The reduced transverse dimension enables closer spacing of multiple connectors along the cable loom, accommodating all necessary cable connections within the limited tower space.
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 a space-saving arrangement of multiple connectors, meets high current-carrying capacity requirements, and ensures accurate cable polarity through mechanical and color coding, reducing assembly complexity and preventing accidental connections.
Implementation Method 1
At least one annular spring element, which encloses the plug-in contact in the coupling contact in a clamped manner and can thus be held clamped
Data Source
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AI summary
The present invention relates to high-current plug-in connectors, in particular to unipolar high-current plug-in connectors for wind turbine generator systems, which can be arranged beside one another in a space-saving manner and can also meet high requirements on the current-carrying capacity. According to the invention, this is achieved in that cross-sections of which the longitudinal extent exceeds the transverse extent are selected for the plug-in and coupling contact. This means that the dimension in the transverse direction can be restricted and simultaneously the cable cross-section and the contact surface required from an electrical point of view are provided by the increased longitudinal extent. Moreover, the plug and the coupling comprise a visible mechanical coding, which prevents accidental reversal of the polarity of adjacently arranged cables.