High Voltage Connector Eccentric Force Distribution

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Solution Overview

Problem

In high power applications, especially in explosive environments like the petroleum or mining industry, existing electrical connectors face challenges with fine mechanical tolerances leading to canting or seizing issues due to the precise cylindrical surfaces, making engagement and disengagement difficult.

Innovation Solution

An electrical connection system featuring a mechanical coupling assembly that distributes driving force to eccentric positions around a central axis, utilizing a geared component with a ratcheting system and racks to ensure equal force distribution, reducing the likelihood of mechanical seizing and facilitating smooth engagement and disengagement of plug and receptacle components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fine mechanical tolerance (0.2 to 0.4 mm) is used between cylindrical surfaces of plug and receptacle, then flame path safety is improved, but mechanical seizing and canting occur making engagement difficult

Engineering Contradiction:

Improveflame path safetyVSAvoidengagement difficulty

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The coupling force application is segmented into multiple distinct points around the central axis rather than concentrated at a single point. This distribution of force application points prevents localized stress concentration that causes seizing, while maintaining the overall coupling effectiveness needed for flame path safety.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The force application points are positioned at asymmetric angular orientations around the central axis, creating an balanced distribution pattern that prevents canting. This asymmetric arrangement ensures that forces are distributed to prevent both seizing and misalignment during engagement.

Inventive Principle:

Principle #4Asymmetry

2Device complexity

If single point force application is used in mechanical coupling, then device complexity is reduced, but mechanical seizing and uneven force distribution occur

Engineering Contradiction:

Improvecoupling mechanism simplicityVSAvoidmechanical seizing

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Multiple force application points are merged into a coordinated system where all points work together to achieve uniform force distribution. This combined approach maintains relative simplicity while eliminating the seizing problems associated with single-point application.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If fine mechanical tolerance is specified for cylindrical surfaces, then connection precision is improved, but manufacturing and assembly difficulty increase

Engineering Contradiction:

Improvecylindrical surface toleranceVSAvoidassembly difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The mechanical coupling assembly pre-establishes the correct spatial relationship and force distribution before the final engagement of cylindrical surfaces. This preliminary positioning action reduces the sensitivity to manufacturing tolerances, making assembly easier while maintaining connection precision.

Inventive Principle:

Principle #10Preliminary action

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 reduces the risk of mechanical seizing and canting, ensuring reliable and efficient connection and disconnection of high-voltage electrical components, enhancing safety and operational efficiency in demanding environments.

Implementation Method 1

comprising a transmission that is arranged to transmit a further portion of the driving force to a second eccentric position

Methodology Applied

Scientific EffectGear transmission: Gear

Implementation Method 2

the mechanical coupling assembly being structured to impart a portion of the driving force at a first eccentric position and comprising a transmission that is arranged to transmit a further portion of the driving force to a second eccentric position

Methodology Applied

Scientific EffectMechanical force distribution: Mechanical Force

Data Source

PatentUS10218119B2Electrical connection system for use in high power applications

Publication Date: 2019.02.26 CONNEC PTY LTD

AI summary

An electrical connection system is described. The electrical connection system comprises a first electrical connection component that is suitable for transmission of power with a voltage level greater than 1 kV. The electrical connection system also comprises a second electrical connection component that is suitable for transmission of power with a voltage level greater than 1 kV and arranged for coupling to the first electrical connection component. The electrical connection system comprises a mechanical coupling assembly for imparting a driving force to drive the first and second electrical connection components relative to each other along a central axis of the electrical connection system and between disengaged and engaged conditions. The mechanical coupling assembly is structured to impart a portion of the driving force at a first eccentric position and comprising a transmission that is arranged to transmit a further portion of the driving force to a second eccentric position. The second eccentric position has an angular orientation around the central axis that is different to that of the first eccentric position.