DC Plug and Socket Interface for Reversible High-Current Connection
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Solution Overview
Problem
Current DC plugs and sockets are confusingly similar to AC plugs and sockets, making them unsuitable for daily use and not representative of DC systems, especially under voltage levels of 400 VDC and 48 VDC.
Innovation Solution
A DC plug and socket design featuring arc-shaped center contact surfaces with symmetrically arranged plug current conductors, allowing for unlimited forward and reverse plugging, and a unique butterfly-wing type structure to differentiate from AC interfaces, enhance current carrying capacity, and reduce contact resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If DC plugs and sockets are designed following three-phase AC plugs and sockets structure, then the design is simple and familiar, but they are easily confused in life and not representative of DC system
Solution Approach 1:
The patent applies asymmetry by designing the DC plug with a unique butterfly-wing type structure that is fundamentally different from traditional AC plug structures. The center contact with arc-shaped side surfaces and symmetrically arranged current conductors creates an asymmetric design relative to AC plugs, making them visually distinguishable and preventing confusion while remaining manufacturable
Solution Approach 2:
The patent inverts the traditional plug design concept by placing current conductors on the side surfaces of the center contact rather than using conventional pin structures. This inversion creates a completely new interface form that is representative of DC systems while avoiding confusion with AC plugs
2Reliability
If aviation plug structure is adopted, then industrial application reliability is improved, but the product becomes complicated to use, heavy in weight and high in cost
Solution Approach 1:
The patent segments the plug structure into distinct functional parts: a center contact for mechanical connection and current conductors for electrical connection. This segmentation allows each part to be optimized independently, reducing overall complexity while maintaining reliability
Solution Approach 2:
The center contact serves multiple functions: it provides mechanical support, establishes electrical connection, and enables unlimited forward and reverse plugging. This multi-functionality reduces the need for additional components, simplifying the overall structure while maintaining industrial reliability
3Power
If center contact with arc-shaped side surfaces and symmetrically arranged current conductors is used, then current carrying capacity is enhanced and contact resistance is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses arc-shaped side surfaces on the center contact instead of flat surfaces. This curvature increases the contact area with the socket, enhancing current carrying capacity and reducing contact resistance. The arc shape also provides tolerance to manufacturing variations, reducing the stringency of precision requirements
Solution Approach 2:
The patent applies different properties to different parts of the center contact: arc-shaped surfaces for enhanced contact, and specifically positioned current conductors for optimal electrical connection. This local optimization improves performance without requiring uniform high precision throughout the entire component
Data Source
AI summary
The present disclosure relates to a direct current (DC) plug, a DC socket and electric equipment. The DC plug is configured to be connected to a DC socket to supply power to an electrical equipment. The DC plug includes: a center contact, including a first center contact side surface, a second center contact side surface, a third center contact side surface and a fourth center contact side surface, wherein the first center contact side surface and the second center contact side surface are oppositely disposed, and the third center contact side surface and the fourth center contact side surface are oppositely disposed; first plug current conductors, disposed on the first center contact side surface and the second center contact side surface; and second plug current conductors, disposed on the third center contact side surface and the fourth center contact side surface.