Manual Disconnect Bolt Cover Interlock Mechanism
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Solution Overview
Problem
Existing manual disconnects for high voltage batteries in electric vehicles do not effectively prevent accidental reconnection, posing risks of electrocution and damage to vehicle systems during servicing or after accidents.
Innovation Solution
A manual disconnect system comprising a housing, base, and plug assembly with fuse terminals and bolt covers, allowing for secure disconnection and reconnection of the battery circuit, with an interlock resistor to ensure safe current flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a manual disconnect is provided for high voltage batteries, then the ability to manually open the circuit is improved, but the risk of accidental reconnection increases
Solution Approach 1:
The bolt cover is designed to prevent the fastener from being removed before the plug assembly is properly connected. This preliminary protective action blocks the harmful sequence of disconnection followed by accidental reconnection, forcing the correct operational sequence where connection must be established first before disconnection is permitted.
Solution Approach 2:
The system requires the plug assembly to be connected to the base first, which then enables the bolt cover to be removed for disconnection. This preliminary connection action ensures that the circuit is properly established before any disconnection operations can occur, preventing accidental reconnection by enforcing a safe operational sequence.
2Reliability
If the disconnect mechanism is made secure with fasteners, then the reliability of connection is improved, but the ease of operation for disconnection worsens
Solution Approach 1:
The disconnect mechanism is segmented into two independent operations: connection (plugging the plug assembly into the base) and disconnection (removing the bolt cover). This segmentation allows the connection to be secure through the fastener while the disconnection is simplified by only needing to remove the bolt cover, not the fastener itself, thus maintaining both reliability and ease of operation.
Solution Approach 2:
The bolt cover acts as an intermediary element between the secure fastener connection and the disconnection operation. It provides a simple removal mechanism that doesn't require undoing the secure fastener, thus maintaining connection security while enabling easy disconnection through this intermediate component.
3Reliability
If the bolt cover prevents fastener removal, then accidental reconnection is prevented, but the device complexity increases
Solution Approach 1:
The bolt cover serves multiple functions: it protects the fastener from unauthorized removal, provides a clear visual indicator of connection status, and enforces the correct operational sequence. By consolidating these multiple protective and指示 functions into a single component, the design achieves high reliability without proportionally increasing complexity.
Solution Approach 2:
The bolt cover provides visual indication of connection status through its presence or absence, and potentially through color coding or positioning. This visual feedback mechanism communicates the connection state clearly without requiring complex indicators, thus maintaining simplicity while enhancing safety and usability.
Data Source
AI summary
A manual disconnect includes a housing and a base attached to the housing by a fastener. The base includes primary terminals. The manual disconnect also includes a plug assembly that includes fuse terminals and a bolt cover. The plug assembly is movable relative to the base between a disconnected position wherein the fuse terminals are not engaged with respective primary terminals, and a primary circuit engaged position, wherein the fuse terminals are engaged with respective primary terminals. When the plug assembly is in the primary circuit engaged position the bolt cover is positioned to prevent the fastener from being removed from the housing. A handle or cover part of the plug assembly is then rotated to a locked position with respect to the base. Then, the plug assembly can be moved further in the insertion direction to close an interlock circuit, allowing current to flow in the primary circuit.