Electrical Component Double Floating Bearing System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical components, such as battery packs, face challenges with high contact resistance and wear due to precise alignment requirements during charging, leading to increased maintenance and installation efforts, especially when used in heavy-duty applications like forklifts and buses.
Innovation Solution
The electrical component features a double floating bearing system with a contact carrier and plug contacts that allow for lateral and angular adjustments, utilizing compensating devices with centering cones and preloading springs to facilitate easy connection and reduce contact resistance, along with guide pins having annularly enlarged outer contours for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flat connections are pressed parallel against each other to minimize contact resistance, then contact resistance is reduced, but precise alignment is required which increases difficulty of operation
Solution Approach 1:
The contact surfaces are designed with a curved contour instead of flat surfaces, allowing them to adapt dynamically to angular deviations and lateral offsets during connection. The curved shape enables automatic alignment compensation, reducing the need for precise manual alignment while maintaining low contact resistance.
Solution Approach 2:
The contact surfaces are designed with specific geometric parameters (curved contour with defined radius) that allow them to accommodate misalignment within a certain range. By changing the shape parameter from flat to curved, the system gains tolerance to positioning errors while maintaining electrical contact quality.
2Productivity
If high charging current is used to ensure rapid charging, then charging speed is improved, but heat load and wear on contact surfaces increase
Solution Approach 1:
The curved contact surfaces enable dynamic adaptation during connection, ensuring optimal contact pressure distribution even under high current loads. This reduces localized stress concentrations that would otherwise lead to increased wear and heat generation at specific contact points.
Solution Approach 2:
The design anticipates high current operation and the associated thermal and mechanical stresses by using curved contact surfaces that distribute loads more evenly. This pre-engineered load distribution cushions against the harmful effects of high current before they can cause excessive wear or overheating.
3Reliability
If manual alignment is performed to achieve precise connection, then contact resistance is reduced, but installation time and effort increase
Solution Approach 1:
The curved contact surfaces enable the connection system to self-align automatically during the mating process. The geometry of the curved surfaces guides the components into proper alignment without requiring manual intervention, thereby reducing installation time while maintaining low contact resistance.
Solution Approach 2:
The dynamic adaptation capability of the curved contact surfaces allows them to automatically adjust to minor misalignments during connection, eliminating the need for time-consuming manual alignment procedures while ensuring reliable electrical contact.
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
This solution reduces contact resistance, increases durability, and simplifies the connection process, leading to lower maintenance and installation efforts, while ensuring reliable and secure power transmission with reduced plug-in forces.
Implementation Method 1
compensating devices with centering cones and preloading springs
Implementation Method 2
guide pins having annularly enlarged outer contours for precise alignment
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
An electrical component (1) having a housing (2) and having a plurality of plug contacts (3, 4, 5, 6). In this case, the plug contact (3-6) is held in a floating manner on a contact mount (7), and the contact mount (7) is held in a floating manner on the housing (2).