DC Plug Connector Switching Layout for Arc Suppression

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Solution Overview

Problem

Conventional plug-in connection systems for high-voltage DC systems face challenges in safely transmitting energy without arcs, which can damage components, and existing solutions are complex and costly, also detracting from user comfort.

Innovation Solution

An arc-reducing plug-in system with a first plug having three contacts and a second plug with split contacts, along with a clockable switching device and control unit that alternately switches on and off switching elements to maintain a continuous electrical connection, effectively suppressing arcs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional locking mechanisms are used to prevent arc damage, then component safety is improved, but device complexity and cost increase

Engineering Contradiction:

Improvecomponent safetyVSAvoidlocking mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical locking mechanisms with electronic switching elements (transistors or thyristors) that automatically control the electrical connection. These switching elements are triggered by voltage thresholds, eliminating the need for mechanical locks while maintaining arc protection through controlled electrical disconnection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The switching elements automatically detect voltage conditions and trigger disconnection when arcs occur, without requiring external control systems or manual intervention. The system self-regulates by using the electrical parameters themselves to control the switching action, reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual locking mechanisms are implemented to prevent arcs, then component safety is improved, but ease of operation deteriorates

Engineering Contradiction:

Improvearc protectionVSAvoiduser comfort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Manual locking mechanisms are replaced with automatic electronic switching elements that respond to voltage conditions. The switching elements trigger disconnection automatically when arc conditions are detected, eliminating the need for user intervention while maintaining protection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The switching elements act as intermediaries between the electrical connection and the load, automatically intervening when arc conditions occur. This intermediary mechanism protects components without requiring user awareness or action.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If switching devices with gases or extinguishing devices are used to reduce arcs, then arc burning time is reduced, but device complexity and cost increase significantly

Engineering Contradiction:

Improvearc burning timeVSAvoidswitching device complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Complex switching devices with gases or extinguishing devices are replaced with simple electronic switching elements (transistors or thyristors). These semiconductor-based switches achieve arc suppression through electronic control without requiring mechanical components, gases, or complex extinguishing mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters of the electrical connection by using switching elements that can rapidly change their resistance state. This allows controlled interruption of current flow to suppress arcs, achieving the same effect as gas-based devices but through electronic parameter changes rather than physical media.

Inventive Principle:

Principle #35Parameter changes

4Device complexity

If conventional plug systems without automatic switching are used, then device simplicity is maintained, but arc damage risk increases

Engineering Contradiction:

Improvesystem simplicityVSAvoidarc damage risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The switching elements are automatically triggered by voltage threshold conditions without requiring external control systems. The system monitors its own electrical parameters and activates protection when needed, maintaining simplicity while adding arc suppression functionality.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Switching elements are introduced as intermediaries in the electrical path between the plug connection and the load. These elements provide automatic arc suppression while requiring minimal additional components, balancing simplicity with protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4554013A1Arc-reducing electrical plug-in connection system

Publication Date: 2025.05.14 LUNATONE INDUSTRIELLE ELEKTRONIK GMBH

Figure 1~2
Figure 3a~3c

AI summary

The invention relates to an arc-reducing electrical connector system (1) for DC voltage systems of at least 100 V, comprising a first connector (2) and a complementary second connector (3) mechanically and electrically connectable thereto, wherein the first connector (2) has three plug contacts (2a, 2b, 2c), two of which plug contacts (2b, 2c) are electrically connected in parallel to each other and form a plug contact pair (2BC), wherein the second connector (3) has three plug contacts (3a, 3b, 3c) corresponding to the plug contacts (2a, 2b, 2c) of the first connector (2), wherein those plug contacts (3b, 3c) of the second connector (3) which are designed to engage with the plug contact pair (2BC) have electrically separate conductors.