High Voltage Connector Locking Pin Assembly
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Solution Overview
Problem
Current high voltage connectors require torque tools for proper assembly, which is not always feasible, leading to potential improper connections.
Innovation Solution
A high voltage electrical connector design featuring a male interconnect with a contact pin and a female interconnect with a locking pin assembly, including a shoulder bolt, compression spring, and recessed section, allowing for secure connection without torque tools by using a compression spring to lock the contact pin in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bolt with flat washer and disc spring is used to connect cable to bus bar, then the connection can be secured, but torque tools are required for proper assembly which increases complexity and time
Solution Approach 1:
The locking pin assembly is designed to be self-operating through spring-loaded mechanism that automatically locks the contact pin in the socket without requiring external torque tools. The compression spring provides the necessary force to engage the locking pin with the locking groove, making the system self-servicing.
Solution Approach 2:
The traditional bolt-torque-mechanism is replaced with a spring-loaded locking pin mechanism. Instead of relying on torque-controlled fastening, the invention uses elastic potential energy stored in the compression spring to provide consistent locking force, substituting complex mechanical torque application with simpler spring mechanics.
2Ease of operation
If torque limiting bolts are provided with connectors, then proper torque can be achieved without torque tools, but the assembly time increases and proper assembly is still not guaranteed
Solution Approach 1:
The locking pin assembly automatically performs the locking function through its spring-loaded mechanism, eliminating the need for operators to manually control torque application. The system self-regulates the engagement force through the compression spring, making the assembly process both faster and more reliable.
Solution Approach 2:
The compression spring is pre-loaded during assembly to provide the necessary locking force from the outset. This preliminary action of spring compression ensures that the locking pin engages the locking groove with the correct force immediately, without requiring additional torque control steps during assembly.
3Productivity
If a locking pin assembly with compression spring is used, then quick and secure connection is achieved, but the device complexity increases
Solution Approach 1:
The locking mechanism is segmented into distinct functional components: the locking pin, compression spring, shoulder bolt, and locking groove. This segmentation allows each component to perform its specific function independently, simplifying the overall design while maintaining quick and secure connection capabilities.
Solution Approach 2:
The locking pin assembly incorporates dynamic elements including the compression spring that can compress and expand, and the locking pin that can move between locked and unlocked positions. This dynamic design enables quick connection and disconnection while maintaining security when locked, balancing simplicity with functional requirements.
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
Enables quick and secure connection of high voltage cables to bus bars without the need for torque tools, ensuring reliable and repeatable locking and unlocking of the contact pin, with visual indicators for proper installation.
Implementation Method 1
a compression spring intermediate the shoulder bolt and the locking pin
Implementation Method 2
The shoulder bolt can have a bolt head end and a threaded end and the locking pin can have a cavity on one end
Data Source
AI summary
A high voltage electrical connector that includes a male interconnect, a female interconnect and a locking pin assembly. The male interconnect includes a contact pin with a locking groove and the female interconnect includes a socket with an axial bore, a transverse passage and an opening connecting the bore to the passage. The locking pin assembly is installed in the passage and has a recessed section and a cylindrical section. The locking pin assembly is movable between a first position, wherein the bore is unobstructed and the contact pin can be freely inserted and removed, and a second position, wherein the cylindrical section of the locking pin extends into the bore. After the contact pin is inserted in the bore and the locking groove aligned with the opening, the locking pin assembly is moved from the first position to the second position and secures the contact pin in the socket.