EV High-Voltage Contactor Blocking Element Design
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Solution Overview
Problem
The installation of high-voltage contactors in electric vehicles is complicated due to the risk of accidental closure under conditions of acceleration or vibration, leading to increased assembly effort and potential safety issues.
Innovation Solution
A switching device with a connecting element that can be controlled between two states, where a blocking element prevents unintentional switching, ensuring the electrical connection between positive and negative power terminals is securely blocked, allowing for simplified assembly by eliminating the need to consider installation direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactors are installed with different axis directions to prevent accidental closure, then safety is improved, but assembly effort and complexity increase
Solution Approach 1:
The blocking element is designed with an asymmetric geometry that only fits in one orientation, forcing the connecting element to be installed in a specific direction. This asymmetric design prevents accidental closure while maintaining a standardized assembly direction for all contactors, thereby reducing assembly complexity.
Solution Approach 2:
The blocking element acts as an intermediary component between the connecting element and the housing. It mediates the positioning and orientation of the connecting element, ensuring correct installation direction while preventing unintended actuation. This intermediary component simplifies the overall assembly process by providing a clear mechanical guide.
2Device complexity
If spring force alone is used to maintain open state, then device simplicity is improved, but protection against acceleration and vibration effects is insufficient
Solution Approach 1:
The blocking element provides preliminary anti-action by mechanically preventing the connecting element from moving toward the closed position before any accidental force (acceleration or vibration) can act on it. The blocking element is positioned to physically block the travel path of the connecting element, counteracting any unintended motion caused by external forces.
Solution Approach 2:
The blocking element is pre-installed in the housing to establish a predetermined blocking position before the connecting element is installed. This preliminary action ensures that the connecting element can only be actuated in the intended direction and cannot be accidentally closed by vibration or acceleration forces.
3Reliability
If blocking element is always engaged to prevent accidental closure, then safety is improved, but controlled switching capability is lost
Solution Approach 1:
The blocking element is designed to be dynamically movable between a blocking position and a retracted position. During normal operation, it can be temporarily moved out of the blocking position to allow the connecting element to switch states. After switching, it automatically returns to the blocking position to prevent accidental closure, thus maintaining both safety and switching capability.
Solution Approach 2:
The blocking element engages in periodic action by alternating between blocking and non-blocking states. It blocks the connecting element during normal operation to prevent accidental closure, and periodically retracts to allow intentional switching. This periodic engagement and disengagement maintains safety while enabling controlled operation.
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 prevents accidental closure of high-voltage contactors during assembly, reducing installation complexity and enabling efficient, automated assembly of contactors in electric vehicles, ensuring safe and reliable electrical connections.
Implementation Method 1
The connecting element can have an armature, for example, which is prestressed by a spring, so that it assumes the position of the second state without further activation.
Implementation Method 2
The connecting element can also have a magnetic coil, for example, which generates a magnetic field when actuated appropriately and moves the armature into the position of the first state.
Data Source
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AI summary
The invention relates to a switching device (100, 200) for the controlled switching of an electrical connection. The switching device (100, 200) has a positive power terminal (101, 201) and a negative power terminal (102, 202). Furthermore, the switching device (100, 200) has a connection element (103), which is designed to controllably electrically couple the positive power terminal (101, 201) and the negative power terminal (102, 202) to one another when in a first state and electrically disconnect the positive power terminal (101, 201) and the negative power terminal (102, 202) from one another when in a second state, and a blocking element (104), which is designed to block the connection element (103) in the second state when in a non-activated state and to release the connection element (103) when in an activated state. The invention further relates to a corresponding method.