Connector Assembly Locking for Verified High-Voltage Fastening
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Solution Overview
Problem
Existing high-voltage connectors face challenges in accurately determining full fastening of high-voltage modules, leading to potential misjudgment and safety risks due to inaccurate visual inspection of fastener engagement, which can result in incomplete connections and safety accidents.
Innovation Solution
A connector design featuring a locking component that rotates between locking and unlocking positions based on the full fastening of high-voltage modules, ensuring the low-voltage module can only move to a final connected position when the high-voltage module is fully fastened, thereby providing accurate detection of complete fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If visual inspection is used to check fastener engagement, then the inspection process is simple, but the accuracy and reliability of determining full fastening is poor
Solution Approach 1:
The patent introduces a locking component as an intermediary mechanism between the fastener and the low-voltage module. This locking component mechanically links the fastening status to the module's position, serving as a mediator that translates the fastener's engagement state into a clear positional indicator, thereby improving detection accuracy without requiring complex inspection equipment
Solution Approach 2:
The locking component automatically responds to the fastening status through mechanical interaction. When the fastener is fully engaged, the locking component autonomously transitions to an unlocked state, allowing the low-voltage module to move to its final position. This self-service mechanism eliminates the need for manual inspection while ensuring accurate fastening status detection
2Device complexity
If visual inspection is used to check fastener engagement, then no additional components are needed, but the inspection efficiency and accuracy are low leading to safety risks
Solution Approach 1:
The locking component performs a preliminary check of the fastening status before allowing the low-voltage module to engage with the mating connector. By mechanically preventing module movement until the fastener is fully engaged, the system ensures that safety-critical fastening is completed before electrical connection, thereby improving reliability without significantly increasing overall structure complexity
Solution Approach 2:
The locking component acts as a safety intermediary that mechanically couples the fastener's engagement state to the module's ability to connect. This intermediary mechanism provides a reliable, fail-safe method for ensuring proper fastening, eliminating the unreliability of visual inspection while maintaining a relatively simple connector structure
3Ease of operation
If the low-voltage module moves synchronously with the high-voltage module, then the connection process is simple, but it is difficult to accurately determine when full fastening has been achieved
Solution Approach 1:
The patent segments the connection process into two distinct phases: a preliminary phase where the low-voltage module moves with the high-voltage module, and a final phase where the low-voltage module's position is controlled by the locking component's state. This segmentation allows the system to maintain operational simplicity while achieving precise detection of fastening completion through the locking component's positional indication
Data Source
AI summary
A connector includes a housing that is matable with a mating housing of a mating connector, a high-voltage module provided in the housing, the high-voltage module electrically connects and fastens to a high-voltage mating module of the mating connector, a low-voltage module movably installed outside the housing, and a locking component rotatably installed outside the housing. The locking component is limited by the high-voltage module to a locking position engaged with the low-voltage module, locking the low-voltage module in a pre installation position separated from a low-voltage mating module of the mating connector, when the high-voltage module is not fully fastened to the high-voltage mating module. The locking component rotates to an unlocking position separated from the low-voltage module, allowing the low-voltage module to move to a final installation position electrically connected to the low-voltage mating module, when the high-voltage module has been fully fastened to the high-voltage mating module.