Connector Arrangement for Simultaneous High-Voltage Cable Crimping
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Solution Overview
Problem
The connection of multiple high-voltage cables to a common connector in electric and hybrid vehicles requires a complex and time-consuming crimping process, leading to increased process time and space requirements due to the need for individual crimping of each cable, which complicates the geometry and space usage of the connector housing.
Innovation Solution
A connector arrangement featuring a crimp barrel that encloses a connector housing with leadthroughs for each cable, allowing for a time-synchronous connection of multiple cables to a single connector through a single crimping operation, utilizing a crimp barrel that frictionally connects the shielding of each cable to the connector housing, made of electrically conductive material, to achieve a stable mechanical and electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple shielded high-voltage cables are connected to a high-voltage connector through individual crimping processes, then reliable electrical connection and mechanical stability are achieved, but process time increases and connector housing geometry becomes more complex
Solution Approach 1:
The patent combines multiple individual crimping operations into a single synchronous crimping process. A common crimping tool applies crimping force simultaneously to multiple cable-connector interfaces through a unified tool geometry, reducing total process time while maintaining connection reliability through consistent force distribution.
Solution Approach 2:
The connector housing is designed with a universal crimping interface that can accommodate multiple cables of different types and sizes. The common crimping tool is equipped with a multi-functional jaw structure that can simultaneously crimp multiple different cable configurations, enhancing productivity without compromising connection quality.
2Reliability
If multiple shielded high-voltage cables are connected to a high-voltage connector through individual crimping processes, then reliable mechanical connection is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent merges multiple cable entry points and crimping zones into a unified connector housing structure. The housing features an integrated design where multiple cables enter through a common interface region, and a single crimping tool geometry manages all crimping operations, simplifying the overall device complexity while maintaining mechanical stability.
Solution Approach 2:
The connector housing is segmented into functional zones: a common entry region for multiple cables, individual cable receptacles with standardized geometries, and a unified crimping interface. This segmentation allows complex multi-cable connections to be managed through modular, repeatable structural units, reducing overall design complexity.
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
This solution enables a simultaneous, efficient connection of multiple cables to a single connector, reducing process time and simplifying the connector housing design, while ensuring a reliable mechanical and electrical connection, suitable for series production and high-voltage applications.
Implementation Method 1
the crimp barrel enclosing the connector housing and each leadthrough, and being frictionally connected to the connector housing
Data Source
AI summary
A connector arrangement comprises at least at least two cables, each comprising one cable sheath, and respectively one shielding arranged within the cable sheath. The shielding is exposed from the cable sheath at one cable end. The connector arrangement additionally comprises a connector housing made of an electrically conductive material, in which there is realized a respective a leadthrough for each cable. The exposed shielding of each cable is located in the respective leadthrough, and is frictionally connected to the connector housing. The connector arrangement also comprises a crimp barrel. The crimp barrel encloses the connector housing and each leadthrough, and is frictionally connected to the connector housing.