DC Plug Contact Assembly for Arc-Free Disconnection
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Solution Overview
Problem
Existing technologies fail to effectively extinguish arcs when disconnecting or closing direct current connections in series or bidirectional networks, leading to potential damage and safety hazards, and require additional diodes for unidirectional applications.
Innovation Solution
A plug contact device with a main contact and an auxiliary contact, each with multiple interconnectable halves, and an electronic switching unit that connects or isolates these contacts to prevent arcs, eliminating the need for diodes by using a galvanically isolated auxiliary contact and an additional forwarding contact to connect to an electronic switching unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic switching components are used to suppress arcs, then arc prevention is achieved, but energy loss increases due to continuous current flow through electronics
Solution Approach 1:
The electronic switching unit operates periodically only during switching events rather than continuously. The control unit activates the electronic switching unit to route current through the auxiliary contact and electronic path only during the arc suppression phase, then returns to normal operation through the main contact, minimizing energy loss while maintaining arc prevention capability.
2Adaptability or versatility
If diodes are installed in supply lines to enable parallel connector operation, then multiple connectors can be supplied, but the solution only works for unidirectional networks and requires additional components
Solution Approach 1:
The control unit acts as an intelligent intermediary that replaces passive diodes with active control logic. The control unit monitors the state of connectors and electronically manages current distribution, enabling bidirectional operation and parallel connector support without requiring physical diodes in each supply line, thus reducing component complexity while increasing adaptability.
Solution Approach 2:
The patent replaces the mechanical/passive diode-based current direction control with an electronic control system. The control unit uses electronic switching and monitoring to manage current flow direction and parallel connector operation, eliminating the need for physical diodes and enabling bidirectional current flow that mechanical diodes cannot support.
3Adaptability or versatility
If the first connector behind electronics is the only one supplied, then electronics can operate simply, but additional series-connected connectors cannot be operated
Solution Approach 1:
The electronic switching unit is designed with multi-functionality to support both single and multiple series-connected connectors. The control unit monitors auxiliary contacts from multiple connectors and dynamically routes current through the electronic switching unit as needed, allowing the same electronic module to serve multiple series-connected connectors without requiring separate electronics for each connector.
4Reliability
If mechanical aids are used to extinguish arcs, then arc suppression is achieved, but connector damage and safety hazards remain
Solution Approach 1:
The electronic switching unit serves as an intermediary that intercepts and redirects the arc current before it can damage the connector contacts. When an arc begins to form at the main contact, the control unit detects this and immediately routes the current through the auxiliary contact and electronic switching unit, which safely dissipates the energy without damaging the mechanical connector components.
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 disconnection or connection in both unidirectional and bidirectional networks, ensuring safe operation and eliminating the need for diodes, thus enhancing energy efficiency and reducing the complexity of series connections.
Implementation Method 1
the HA of the at least two connectors is designed to electrically connect the HI1 and the HI2 in the first intermediate state T1 of the respective connector between the plugged-in state T0 and the unplugged state T3
Implementation Method 2
using a galvanically isolated auxiliary contact and an additional forwarding contact to connect to an electronic switching unit
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~4C
AI summary
The invention relates to a plug contact apparatus (100) for extinguishing an electric arc using an extension, comprising a main contact, HA (112), and an auxiliary contact, Hl (114). HA (112) and Hl (114) each comprise a first contact half, HA1 (112-1) and Hl1 (114-1) respectively, and a second contact half, HA2 (112-2) and HI2 (114-2) respectively, which can be detachably plugged together. In the plugged-together state T0, HA (112) electrically connects HA1 (112-1) and HA2 (112-2), whereas Hl (114) galvanically separates Hl1 (114-1) and HI2 (114-2) in To. In the detached state T3, both HA1 (112-1) and HA2 (112-2) as well as Hl1 (114-1) and HI2 (114-2) are galvanically separated. In the first intermediate state T1 between T0 and T3, both HA1 (112-1) and HA2 (112-2) as well as Hl1 (114-1) and HI2 (114-2) are each electrically connected. In the second intermediate state T3 between T1 and T3, HA1 (112-1) and HA2 (112-2) are galvanically separated and HA2 (112-2) and HI2 (114-2) are electrically connected. An electronic switch unit (120) connects HA1 (112-1) to Hl1 (114-1) in response to a transition from T0 to T1 of a plug connector (110). These are separated in response to a transition from T1 to T3 and/or from T2 to T3.