Electrical Coupler Lid Kinematics for Multi-Car Vehicle Connections
Solution Overview
Problem
Existing electrical couplers for multi-car vehicles require complex mechanical designs to move lids from a closed to an open position, necessitating substantial space and intricate kinematics, which complicates the connection process between cars.
Innovation Solution
The electrical coupler design allows the lid to move from a closed to an open position with reduced space usage by having the housing contact surface cross a reference plane closer to the base plane, simplifying the kinematics and reducing the distance the lid needs to travel, with a separate insulation block providing flexibility in cable connection designs and a straightforward connection mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lid is moved from closed to open position using conventional kinematics, then the lid can be opened, but the mechanism requires substantial space and complex design
Solution Approach 1:
The patent inverts the conventional approach by having the housing contact surface cross the reference plane during lid movement, rather than having the lid move along a fixed arc. This inversion simplifies the kinematic chain and reduces the space required for lid operation.
Solution Approach 2:
The patent changes the movement parameter of the lid by defining the housing contact surface trajectory to cross the reference plane at a specific point. This parameter change transforms the complex multi-axis rotation into a simpler movement that requires less space and mechanical complexity.
2Volume of moving object
If the housing contact surface crosses the reference plane closer to the base plane, then the lid movement space is reduced, but the sealing reliability must be maintained
Solution Approach 1:
The patent applies preliminary action by pre-positioning the housing contact surface to cross the reference plane at an optimized location. This preliminary design ensures that the lid follows the correct trajectory that both reduces movement space and maintains sealing contact, preventing reliability issues before they occur.
Solution Approach 2:
The housing contact surface acts as an intermediary element that mediates between the lid movement requirement and the sealing requirement. By optimizing its trajectory to cross the reference plane, it simultaneously achieves space reduction and sealing reliability.
3Adaptability or versatility
If a separate insulation block is used, then flexibility in cable connection design is improved, but the number of components increases
Solution Approach 1:
The patent segments the electrical coupler into distinct functional components: the housing, the separate insulation block, and the lid. This segmentation allows the insulation block to be independently designed and optimized for different cable connection configurations, providing flexibility without requiring complete redesign of the entire coupler.
Solution Approach 2:
The separate insulation block serves multiple functions: providing electrical insulation, supporting various cable connection configurations, and facilitating assembly. This multi-functionality justifies the additional component by reducing the need for multiple specialized components.
Data Source
AI summary
An electrical coupler comprising a housing with an end opening, an insulation block arranged in the end opening, a lid having an open position and a closed position, an arm attached to the lid and to the housing, whereby attachment of the arm to the housing allows a rotation of the arm relative to the housing around a rotational axis, and optionally a series of arms connected to each other to allow one arm to rotate relative to a neighbouring arm. The lid further comprises a housing contact surface that contacts or is in close proximity to a lid contact surface of the housing, a reference line through the point of the lid contact surface furthest away from the base plane, and wherein a part of the housing contact surface crosses a reference plane closer to the base plane than the reference line is, as the lid is moved from the closed to the open position.