High-Current Connector Assembly With Temperature Sensing and IP67 Locking
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Solution Overview
Problem
Existing high current connectors for energy storage systems lack temperature monitoring, quick-lock functionality, finger touch prevention, IP67 waterproof performance, and 360-degree rotation capability, making them inadequate for safe and efficient operation in energy storage applications.
Innovation Solution
A connector with a housing, terminal, and integrated temperature sensor for real-time temperature detection, along with a locking device featuring an elastic ring and locking member for easy mating and separation, and a sealing mechanism for waterproofing, allowing 360-degree rotation and finger protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing high current connectors are used without temperature sensors, then the connector structure remains simple, but real-time temperature monitoring capability is lost
Solution Approach 1:
The temperature sensor is integrated directly into the connector housing, merging the monitoring function with the connector structure. The sensor is positioned to be in close proximity to the terminal contact area, allowing it to monitor temperature without requiring separate external monitoring equipment.
Solution Approach 2:
The connector performs self-monitoring of its own temperature through the integrated sensor, eliminating the need for external temperature monitoring systems. The sensor detects temperature at the critical contact point and provides feedback that can trigger protective actions.
2Ease of operation
If existing connectors lack quick-lock function, then the connector structure remains simple, but unlocking convenience deteriorates
Solution Approach 1:
The locking mechanism uses spring-loaded locking members that dynamically engage and disengage. The locking members are biased by springs to automatically engage with corresponding features on the mating connector, and can be easily released by applying force to release levers that overcome the spring force.
Solution Approach 2:
The locking function is segmented into multiple independent locking members distributed around the connector perimeter. Each locking member operates independently but works together with the others to provide secure locking. The release levers are also segmented, allowing partial or full release of the locking mechanism.
3Reliability
If existing connectors lack sealing mechanism, then the connector structure remains simple, but waterproof performance deteriorates
Solution Approach 1:
The sealing mechanism uses flexible sealing rings made of elastomeric material that conform to the mating surfaces. The sealing rings are compressed between the connector housing and the mating connector housing, creating a waterproof barrier. The flexibility of the sealing rings allows them to accommodate minor dimensional variations and maintain the seal.
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 solution enables real-time temperature monitoring, secure and easy connector operation, enhanced safety through waterproofing, and improved usability with 360-degree rotation, addressing the shortcomings of existing connectors.
Implementation Method 1
a temperature sensor inserted into the insertion hole of the housing and in thermal contact with the terminal to detect the temperature of the terminal
Data Source
AI summary
A connector assembly comprises a connector, a mating connector, and a locking device detachably mounted on the mating connector and adapted to lock the connector and the mating connector in a mating state. The connector includes a housing having an insertion hole, a terminal provided in the housing, and a temperature sensor inserted into the insertion hole of the housing and in thermal contact with the terminal to detect the temperature of the terminal.