Contactor Box Assembly for Automatic High-Voltage Disconnect
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical energy storage systems in vehicles face challenges with the safe and easy removal and installation of contactor boxes due to high voltage and current risks, particularly with levered connectors requiring manual disconnection.
Innovation Solution
A contactor box design with automatically disengaging incoming and outgoing high voltage connections that can be easily pulled or lifted for removal, along with a fastening device and handle for secure attachment and handling, reducing manual disconnection risks and improving accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If levered connectors are used for high voltage connections, then connection reliability is improved, but manual disconnection complexity and safety risks increase
Solution Approach 1:
The contactor box is designed to automatically disconnect high voltage connections through its own removal action. When the contactor box is pulled out from the battery assembly, the integrated high voltage connections automatically disengage without requiring external manual intervention, making the system serve itself in the disconnection process
Solution Approach 2:
The high voltage connections are merged with the contactor box structure itself, forming an integrated assembly. This combination means that removing the contactor box automatically removes the high voltage connections together, eliminating the need for separate manual disconnection steps and reducing safety risks associated with exposed high voltage terminals
2Reliability
If high voltage connections are permanently fixed, then connection reliability is improved, but removal and installation difficulty increase
Solution Approach 1:
The electrical energy storage system is segmented into modular components: the battery assembly, the contactor box, and the high voltage connections. This segmentation allows the contactor box to be easily removed and reinstalled while maintaining reliable connections during operation, facilitating maintenance and repair activities
3Stability of the object's composition
If manual disconnection procedures are used, then connection stability is improved, but time consumption and productivity decrease
Solution Approach 1:
The contactor box is designed with pre-integrated high voltage connections that are prepared for automatic disengagement. This preliminary configuration ensures that when the contactor box is removed, the high voltage connections are already positioned to automatically disconnect, eliminating the need for time-consuming manual disconnection procedures while maintaining connection stability during operation
Data Source
AI summary
The present disclosure relates to a contactor box (201) for an electrical energy storage system (200) of an at least partly electrical vehicle (100). The contactor box (201) comprises a first ingoing high voltage connection (203a) adapted to be connected to a second ingoing high voltage connection (203b) of a battery (210). The contactor box (201) comprises a first outgoing high voltage connection (205a) adapted to be connected to a second outgoing high voltage connection (205b) of the battery (210). The first ingoing and the first outgoing high voltage connections (203a, 205a) are adapted to be disengaged from the battery (210) when the contactor box (201) is removed from the vehicle (100), and adapted to be engaged with the battery (210) when the contactor box (201) is inserted into the vehicle (100).