Systems and methods for testing electrical connectors
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Solution Overview
Problem
Current electrical connectors for refrigerated shipping containers lack electrical testing features, leading to potential unsafe conditions due to undetected damage during transportation and storage, which can result in equipment damage and safety risks.
Innovation Solution
An electrical connector testing system with a controller that determines adverse electrical conditions before allowing power flow, incorporating a reefer receptacle with an electrical interlock, breaker, and power supply, which performs tests to ensure safe operation by preventing energization in case of unsafe conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical interlocking features are used in receptacles, then proper insertion of connectors is ensured, but electrical testing features are not provided
Solution Approach 1:
The patent combines mechanical interlocking features with electrical testing features into a single integrated receptacle system. The testing contacts are integrated within the receptacle housing, allowing both mechanical connection and electrical testing to occur through the same physical interface, thereby resolving the contradiction between reliability of insertion and adaptability for testing.
Solution Approach 2:
The receptacle is designed to perform multiple functions: mechanical interlocking for secure connection, electrical continuity testing, ground fault detection, and breaker testing. This multi-functional design allows the same receptacle structure to provide both reliable connection and comprehensive electrical testing capabilities.
2Reliability
If electrical testing features are added to connectors, then unsafe conditions can be detected, but device complexity increases
Solution Approach 1:
The patent introduces a separate controller as an intermediary device that performs the electrical testing functions. Rather than embedding complex testing circuitry directly in the connector, the controller acts as a mediator that manages the testing sequence, processes results, and controls power delivery, thereby reducing complexity in the connector itself while maintaining comprehensive safety detection.
Solution Approach 2:
The system performs self-testing through automated sequences where the controller tests continuity, ground faults, and breaker functionality before allowing power delivery. This self-service capability eliminates the need for manual testing procedures and reduces the complexity of external testing equipment while ensuring safety.
3Reliability
If electrical testing is performed before power delivery, then equipment damage is prevented, but time is lost during testing
Solution Approach 1:
The controller performs all necessary electrical tests (continuity, ground fault, breaker functionality) before allowing power delivery to the reefer container. This preliminary action ensures that any potential safety issues are identified and addressed before equipment is energized, preventing damage while establishing a standardized testing sequence that minimizes unnecessary delays.
Solution Approach 2:
The testing system is designed to quickly perform essential safety checks by skipping non-critical measurements and focusing only on parameters that could cause equipment damage or safety hazards. This approach rushes through the minimum necessary testing sequence to enable rapid safe power delivery.
Data Source
AI summary
An electrical connector testing system can include a first connector end and a controller coupled to first connector end. The system can also include an electrical load coupled to the first connector end, where the electrical load includes an electrical cable and a second connector end coupled to an end of the electrical cable. The controller can determine whether an adverse electrical condition exists with respect to the electrical load before allowing power to flow between the first connector end and the second connector end.