Reconfigurable Connector Adapter for Multi-Current Power Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connector systems for distributing power in automotive and machine control applications require multiple fuses and overload protection levels due to varying wire sizes and current capacities, leading to complexity and inefficiency.
Innovation Solution
A reconfigurable connector system comprising an energy center module with electronic fuses and a controller, along with a connecting adapter featuring bridging adapters that can be configured to connect with multiple pin holes, allowing for customizable power distribution based on varying current requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fuses and overload protection levels are used for different wire sizes and current capacities, then power distribution safety is improved, but system complexity increases
Solution Approach 1:
The patent implements a universal fuseless power distribution system where a single reconfigurable connector system can accommodate multiple wire sizes and current capacities through software-controlled electronic fuses. The system provides overload protection for different current ratings (e.g., 10A, 20A, 30A, 40A, 50A) using a single physical connector design, eliminating the need for multiple specialized connectors and physical fuses for each wire gauge. The controller dynamically configures the connector's electrical connections based on the detected wire size and required current capacity.
Solution Approach 2:
The system changes its operational parameters dynamically based on the connected wire size and current requirements. The controller adjusts the electrical resistance, connection configuration, and protection levels by modifying the state of solid-state circuit components rather than relying on fixed physical fuse ratings. This allows the same physical connector to adapt its electrical characteristics to match different load requirements.
2Device complexity
If a fixed connector design is used for all current capacities, then device complexity is reduced, but adaptability to different current requirements deteriorates
Solution Approach 1:
The connector system transitions from a static, fixed design to a dynamic, reconfigurable system. The controller continuously monitors the connected load and wire size, then dynamically reconfigures the internal electrical connections and protection parameters. Solid-state circuit components can be rapidly switched and reconfigured without mechanical movement, allowing the connector to adapt its electrical characteristics in real-time to different current requirements while maintaining a single physical design.
Solution Approach 2:
The patent replaces traditional mechanical fuse links and physical connector variations with electronic control systems. Instead of using mechanical fuses that must be physically installed or replaced, the system uses electronically controlled switches, resistors, and protection circuits that can be reconfigured through software. This substitution of mechanical elements with electronic components enables a single connector design to provide multiple current capacity configurations.
Data Source
AI summary
A reconfigurable connector system for distributing power between an input power source and a cable harness connector having M cable harness terminals includes an energy center module (ECM) and a connecting adapter. The ECM has a module housing, a PCB having more than M pin holes, a plurality of e-fuses connected with the pin holes, a controller connected with the e-fuses, and an input connector connected to the controller and/or the e-fuses. The connecting adapter has a body with first and second sides and M bridging adapters within the body. Each bridging adapter includes a first connection point accessible from the first side and configured to be directly connectable with a cable harness terminal, one or more second connection points accessible from the second side and configured to be connectable with a pin hole, and a busbar connecting the first connection point with the one or more second connection points.