Connector Contactless Position Detection
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Solution Overview
Problem
Existing connectors in the automotive sector, particularly HVIL systems, face challenges in accurately detecting the position of the plug relative to the socket and the locking mechanism without physical contact, leading to potential corrosion and incorrect switching due to separate sealing of auxiliary contacts, which can result in unreliable operation.
Innovation Solution
A connector design incorporating contactless position detection elements, such as Hall sensors, reed switches, or RFID technology, positioned on the plug and socket or locking mechanism, allowing for non-contact detection of the plug's position and locking status, enabling load-free switching and eliminating the need for mechanical coding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If auxiliary contacts are offset from power transmission contacts and sealed separately, then position detection can be achieved, but sealing complexity increases and reliability decreases
Solution Approach 1:
The patent combines the sealing of auxiliary contacts and power transmission contacts into a single integrated sealing structure. The sealing element (rubber diaphragm) is continuous and encompasses both the auxiliary contacts and power transmission contacts, eliminating separate sealing requirements and ensuring uniform protection against moisture and corrosion for all contacts.
2Measurement precision
If auxiliary contacts are used for position detection, then contact position can be detected, but corrosion and aging affect detection reliability
Solution Approach 1:
The patent replaces the mechanical contact-based auxiliary contacts with a contactless detection system using magnetic fields. A magnetic detector on the socket side detects the position of a magnetic element on the plug side without physical contact. This eliminates wear, corrosion, and aging effects associated with mechanical contacts while maintaining position detection accuracy.
3Adaptability or versatility
If mechanical coding is used for plug identification, then specific socket compatibility can be ensured, but position and locking status cannot be detected
Solution Approach 1:
The patent implements a multi-functional detection system that simultaneously provides plug identification, position detection, and locking status detection. The magnetic field-based detection system can identify the plug type, determine its position during insertion, and verify locking status, replacing multiple separate mechanisms with a single universal detection approach.
4Reliability
If contactless position detection is implemented, then sealing is improved, but device complexity increases
Solution Approach 1:
The patent extracts the detection function from the mechanical contact system and implements it separately using magnetic field interaction. The magnetic detector and magnetic element operate independently of the contact mechanism, allowing for a cleaner, more integrated sealing structure while maintaining detection functionality through a relatively simple magnetic field-based system.
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 allows for reliable detection of the plug's position and locking status, ensuring correct connection and preventing corrosion, while being inexpensive, easy to produce, and seal, thus enhancing the reliability and durability of the connector.
Implementation Method 1
the first position detection element is a Hall sensor or a reed switch. The second position sensing element is a permanent magnet or a magnetized ferrite. The Hall sensor or reed switch reacts to the permanent magnet or the magnetized ferrite
Implementation Method 2
The second position sensing element is a permanent magnet or a magnetized ferrite
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a connector consisting of a plug and a socket, wherein the connector has a first and a second position sensing element which are designed to detect a position of the plug relative to the socket and/or a position of a locking mechanism of the connector without contact.