Compact High-Voltage Connector With Segmented Interlock Mechanism
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Solution Overview
Problem
Existing high-voltage unit connectors with interlock mechanisms are bulky due to a common sidewall surrounding multiple connectors, limiting design flexibility and increasing the size of the high-voltage unit case.
Innovation Solution
A compact connector design with an interlock mechanism where each connector terminal is spaced apart and surrounded by a sidewall, with a detachable protection cover and an interlock pin that interrupts current flow when detached, allowing for separate placement and reduced overall size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a common sidewall surrounds multiple connectors, then the interlock mechanism can be shared, but the overall size increases and design flexibility decreases
Solution Approach 1:
The patent divides the connector structure into separate individual connectors, each with its own sidewall and interlock mechanism, rather than using a common sidewall for multiple connectors. This segmentation allows each connector to be independently sized and positioned, reducing the overall volume of the high-voltage unit case while maintaining full interlock functionality for each connector.
2Adaptability or versatility
If separate sidewalls and interlock mechanisms are provided at each connector, then design flexibility increases, but the connector size increases due to additional regions required
Solution Approach 1:
The patent merges the interlock mechanism into the protection cover itself, where the cover includes an interlock protrusion that directly engages with the connector body. This integration eliminates the need for separate interlock mechanism components, allowing design flexibility while preventing connector size increase.
3Reliability
If the protection cover is made detachable for safety, then worker protection is enabled, but the connector structure becomes more complex
Solution Approach 1:
The protection cover serves multiple functions simultaneously: it provides physical protection for the connector terminals, acts as the interlock mechanism through its protrusion structure, and enables safety isolation by being detachable. This multi-functionality achieves worker safety while minimizing structural complexity.
Data Source
AI summary
A connector includes: a first connector terminal to which a first electric cable is to be connected; a second connector terminal to which a second electric cable is to be connected; a sidewall that surrounds the first connector terminal and the second connector terminal; a protection cover; and an interlock mechanism. The interlock mechanism includes an interlock connector and an interlock pin. The interlock connector is disposed between the first connector terminal and the second connector terminal, and the interlock pin is provided at the protection cover and is positioned such that the interlock pin is inserted into the interlock connector when the protection cover is attached to the sidewall.