Electrical Connector Pre-Plugging to Prevent Misplug in Energy Storage
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Solution Overview
Problem
The issue of wrong plugging and mis-plugging during the installation of energy storage systems leads to safety risks and economic losses due to complex high-voltage connections and inadequate installer training, resulting in short-circuit accidents.
Innovation Solution
An electrical connector with a receptacle and plug that can be switched between a pre-plugging state (insulating connection) and an electrically-plugging state (electrical connection) to ensure safe delivery and easy on-site installation, featuring distinct plugging positions or modes to prevent incorrect connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the plug and receptacle are separated for delivery to ensure safety, then safety during transportation is improved, but the complexity of installation operation increases and wrong plugging may occur
Solution Approach 1:
The plug and receptacle are pre-assembled into a complete wire assembly at the factory before delivery. This preliminary assembly ensures that the connection structure is already in place, reducing installation complexity on-site while maintaining safety through proper packaging and handling procedures during transportation.
2Ease of operation
If the plug and receptacle are assembled before delivery to simplify installation, then ease of operation is improved, but safety risks increase due to potential short-circuits
Solution Approach 1:
The wire assembly is segmented into modular components (plug, receptacle, cable) that can be pre-assembled at the factory in a controlled environment, then separated into manageable sections for safe transportation and storage. On-site, these segments are easily reassembled by simply connecting the plug to the receptacle, simplifying installation while maintaining safety through the controlled segmentation and storage of electrically isolated components.
3Adaptability or versatility
If multiple plugs and receptacles are provided for complex high-voltage connections, then adaptability is improved, but the likelihood of wrong plugging increases
Solution Approach 1:
The plug and receptacle designs incorporate asymmetric features such as keyed interfaces, shaped connectors, or position-coded arrangements that allow only the correct plug to mate with its corresponding receptacle. This asymmetric design physically prevents wrong plugging attempts, ensuring connection accuracy while maintaining the ability to accommodate multiple different connection configurations through various plug-receptacle pairs.
Data Source
AI summary
An electrical connector includes: a receptacle having a mating socket and a device-side interface, the device-side interface being configured to be electrically connected to an electrical apparatus and secured to the electrical apparatus; and a plug, provided with an electrical plug and a wire interface. The receptacle and the plug can be plugged together by means of the cooperation between the mating socket and the electrical plug; the wire interface is configured to be electrically connected to a wire; the plug is configured to have a pre-plugged state so as to be in insulating connection with the receptacle, and to have an electrically-plugged state so as to be in electrical connection with the receptacle; in the pre-plugged state, the plug is detachably connected to the receptacle. The electrical connector provided by the technical solution of the present application can solve the problems of erroneous plugging and misplug.