High-Voltage Connector Sleeve for Partial Discharge Suppression
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Solution Overview
Problem
Existing connectors used in the railway industry for high current and voltage transmission are prone to partial discharges due to their complex geometry, particularly in the connection or crimping area.
Innovation Solution
A connector design featuring a partial discharge sleeve that encases the connection part of the contact element, providing a homogeneous potential and rounded surface to prevent partial discharges, with a conductive material like aluminum and a non-conductive outer layer for a homogeneous transition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a two-part contact element with orthogonal arrangement is used, then the connector can transmit high currents and enable angled cable connections, but partial discharges occur locally in the connection area due to complex geometry
Solution Approach 1:
A partial discharge sleeve is introduced as an intermediary component between the contact element and the surrounding environment. This sleeve acts as a mediator that shapes the electric field distribution and prevents partial discharges by providing a controlled transition zone, thereby protecting the connector while maintaining its high current transmission capability
Solution Approach 2:
The partial discharge sleeve modifies the geometric parameters of the connection area by providing a rounded, gradually transitioning shape instead of sharp edges or abrupt geometry changes. This parameter change in the physical dimensions and contours of the connection zone eliminates the conditions that lead to partial discharges
2Adaptability or versatility
If the contact element has a complex orthogonal geometry, then angled connections are enabled, but the surface becomes non-homogeneous with adjacent air gaps that cause partial discharges
Solution Approach 1:
The partial discharge sleeve serves as an intermediary that bridges the geometric discontinuities created by the orthogonal contact element arrangement. It provides a continuous, homogeneous surface that eliminates air gaps while preserving the underlying angled connection functionality of the contact element
Solution Approach 2:
The partial discharge sleeve features a rounded, curved geometry that replaces sharp edges and abrupt transitions. This spheroidal shape creates a homogeneous surface without air gaps, eliminating the conditions for partial discharges while the internal structure maintains the orthogonal arrangement for angled connections
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
The design effectively prevents partial discharges, enabling higher operating voltages and reliable electrical contact, thus enhancing the connector's performance.
Implementation Method 1
By enclosing the connection part of the contact element with the partial discharge sleeve, a uniform potential is established inside the partial discharge sleeve
Implementation Method 2
Preferably, the non-conductive material is applied to the partial discharge sleeve using an injection molding process
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a plug connector (1) comprising a plug connector housing (2), an insulating body (3) and at least one two-part contact element (4) consisting of a connection part (4a) and a contact part (4b), wherein the plug connector (1) further comprises a partial discharge sleeve (7) and wherein the connection part (4a) of the contact element (4) is arranged at least partially within the partial discharge sleeve (7).