DC Plug-In Contact with Auxiliary Switching for Arc-Free Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plug-in connectors for direct current (DC) connections face challenges in preventing arcs during separation or connection, leading to damage and safety risks, and existing solutions are inadequate for bidirectional networks.
Innovation Solution
A plug-in contact device with a main contact and an auxiliary contact, each having releasable halves, and an electronic switching unit that manages impedance transitions to prevent arcs, allowing operation in both unidirectional and bidirectional networks without the need for additional diodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical arc extinguishing methods (sacrificial zones, blow magnets) are used, then arc damage is reduced, but device complexity and energy loss increase
Solution Approach 1:
The patent replaces mechanical arc extinguishing methods (sacrificial zones, blow magnets) with an electronic switching system using semiconductor components (IGBTs, MOSFETs). The electronic switch interrupts the current flow before the contacts separate, preventing arc formation without requiring additional mechanical components.
Solution Approach 2:
The patent introduces an auxiliary contact and electronic switching unit as an intermediary between the main contact and the load. This intermediary system handles the current interruption electronically, protecting the main contacts from arc damage while maintaining bidirectional current flow capability.
2Reliability
If electronic spark extinguishing is used with diodes in leads, then arc is prevented in unidirectional networks, but bidirectional current flow is blocked and device complexity increases
Solution Approach 1:
The patent employs dynamic control of the electronic switching unit that can adapt its operation based on current direction. The switching unit responds to voltage polarity changes and adjusts its switching timing to accommodate bidirectional current flow, enabling the system to handle both motor and generator operations of electric machines.
Solution Approach 2:
The electronic switching unit is designed to perform multiple functions: it prevents arcs during contact separation, enables bidirectional current flow, and works with multiple plug-in connectors through a single module. The auxiliary contact configuration allows the same electronic unit to serve unidirectional and bidirectional applications.
3Reliability
If current flows permanently via electronics, then arc is eliminated, but energy loss increases continuously
Solution Approach 1:
The electronic switching unit operates periodically only during the brief switching transient when contacts are separating or closing. Once the contacts are firmly connected or disconnected, the electronic switch remains non-conductive, allowing current to flow only through the low-resistance contact path during normal operation, minimizing energy loss.
Solution Approach 2:
The electronic switching unit activates in advance before the main contacts separate to interrupt the current flow. By switching off the current beforehand, the system prevents arc formation at the moment of contact separation while allowing the contacts to remain in their low-resistance connected state during normal operation.
4Device complexity
If multiple plug-in connectors are supplied by a single electronic module, then device complexity is reduced, but short circuit risk between strands increases
Solution Approach 1:
The patent divides the system into independent plug-in connector units, each with its own auxiliary contact that is galvanically separated from others when disconnected. The electronic switching unit processes each connector's switching event independently through the auxiliary contacts, preventing current paths between different connector strands while allowing a single shared electronic module to serve all connectors.
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 effectively prevents arcs during DC connection and disconnection, protecting the connector and ensuring safety while supporting bidirectional current flow without additional components like diodes.
Implementation Method 1
decrease an impedance between the first terminal and the second terminal
Implementation Method 2
electrically conductively connect the first terminal and the second terminal
Data Source
AI summary
A plug-in contact device for preventing or extinguishing an arc when separating or closing a direct current connection includes: at least one plug-in connector each having a main contact, HA, and an auxiliary contact, HI, the HA including a first contact half, HA1, and a second contact half, HA2, which are releasably plugged together. The HA: electrically conductively connects the HA1 and the HA2 in a plugged-together state of the respective plug-in connector, galvanically separates the HA1 and the HA2 in a released state of the respective plug-in connector, electrically conductively connects the HA1 and the HA2 in a first intermediate state of the respective plug-in connector between the plugged-together state and the released state, and galvanically separates the HA1 and the HA2 in a second intermediate state of the respective plug-in connector between the first intermediate state and the released state.