Embedded Sensor High-Voltage Connector
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Solution Overview
Problem
Existing high-voltage T-format connectors face issues with sensor placement and interference, as external sensors complicate installation and lack manufacturer control, leading to potential errors and interactions with other elements.
Innovation Solution
Embedding sensors within the insulating body of the connector, such as coil-shaped current sensors and resistive or capacitive voltage sensors, allows for controlled placement and reduced interference, maintaining a compact design and ensuring proper sensor orientation during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sensors are placed externally on the connector, then installation and measurement are simplified, but interference with other elements and lack of manufacturer control occur
Solution Approach 1:
The patent merges the sensor with the connector body by embedding the sensor directly into the insulating material during the molding process. This integration eliminates the need for separate sensor installation and prevents interference with external elements, as the sensor becomes an intrinsic part of the connector structure.
Solution Approach 2:
The sensor is nested within the insulating body of the connector, with the insulating material molded around the sensor. This nesting approach allows the sensor to be positioned precisely within the connector structure while maintaining electrical insulation and mechanical protection.
2Measurement precision
If sensors are embedded in the insulating body, then manufacturer control and measurement accuracy improve, but manufacturing complexity increases
Solution Approach 1:
The sensor is positioned and prepared before the insulating material is molded. The connector manufacturer places the sensor in the desired position within the mold cavity, then proceeds with the molding process to encapsulate the sensor. This preliminary positioning ensures precise sensor placement and orientation while utilizing standard molding processes.
Solution Approach 2:
The insulating material acts as an intermediary that both protects the sensor and provides structural integration. The molding process serves as the mechanism to embed the sensor securely within the insulating body, transforming a potentially complex assembly operation into a single integrated manufacturing step.
3Measurement precision
If voltage sensor is placed in the second internal channel, then voltage measurement is enabled, but the channel cannot serve for connection to other elements
Solution Approach 1:
The voltage sensor is moved from occupying the internal channel space to being embedded within the insulating body. This dimensional relocation allows the internal channel to remain open and available for conductor connections while the sensor measures voltage through the insulating material, eliminating the trade-off between measurement capability and connection versatility.
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 provides a compact, interference-free high-voltage connector with embedded sensors, ensuring accurate measurements and reducing errors by allowing the connector manufacturer to control sensor placement and orientation, maintaining insulation and operational efficiency.
Implementation Method 1
coil-shaped current sensors
Implementation Method 2
resistive or capacitive voltage sensors
Data Source
Figure 1~2
Figure 3~4
AI summary
The high-voltage connector comprises an insulating body (1, 2) with an initial internal channel (3) and a second internal channel (4), configured to receive a bushing or a fixed base of a high-voltage equipment. The connector comprises at least one sensor (5, 6, 7, 8) of an electric feature at least partially embedded inside the insulating body.