EV Input Connector Assembly With Integrated Residual Current Detection
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Solution Overview
Problem
Existing residual current detection systems in electric vehicles suffer from significant power loss and assembly complexity due to direct wire connection methods.
Innovation Solution
An input connector with an integrated residual current detection (RCD) sensor, featuring a wire terminal block, lock and release mechanism, and a support holder, allows residual current detection without direct wire connection, using a compact design with minimal power loss and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct wire connection methods are used for residual current detection, then the detection function is achieved, but power loss increases and assembly complexity increases
Solution Approach 1:
The patent introduces an intermediary magnetic core structure that couples the wire terminals to the residual current sensor without direct electrical connection. The magnetic core acts as a mediator that transfers magnetic flux from the current-carrying wires to the sensor, enabling residual current detection while eliminating the need for direct wire connection to the sensor, thus reducing power loss and assembly complexity
2Reliability
If direct wire connection methods are used for residual current detection, then the detection function is achieved, but assembly complexity increases
Solution Approach 1:
The patent merges the wire terminal block and residual current sensor into a single integrated assembly. The magnetic core structure is designed to be received within the wire terminal block, combining multiple functions (wire termination, magnetic coupling, and current sensing) into one compact unit. This integration simplifies assembly by reducing the number of separate components and connection steps required
Solution Approach 2:
The magnetic core serves as an intermediary element that simplifies the assembly process by providing a pre-configured coupling mechanism between the wire terminals and sensor. Instead of requiring complex direct wire connections to the sensor, the magnetic core mediates the connection, allowing for simpler assembly procedures and reduced assembly complexity
3Loss of energy
If integrated RCD sensor construction is used, then power loss is minimized, but manufacturing precision requirements increase
Solution Approach 1:
The patent segments the integrated assembly into distinct modular components: wire terminal block, magnetic core, and residual current sensor. Each component can be manufactured and tested separately with standard tolerances, then assembled together. This segmentation reduces the overall manufacturing precision requirements compared to manufacturing a fully integrated monolithic structure, while still achieving the power loss benefits of the integrated design
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 provides efficient residual current detection with minimal power loss and simplified assembly, enabling cost-effective production through robotic assembly.
Implementation Method 1
residual current sensor adapted to be mounted to a flat surface
Data Source
AI summary
An input connector assembly, which is for detecting residual current and adapted for connecting power sources to electric equipment of electric vehicles, includes a wire terminal block, lock and release mechanisms, a residual current sensor, and a support holder. The wire terminal block has wire terminals for receiving electrical wires. The lock and release mechanisms are connected to the wire terminal block for fixing electrical wires to conductors in the wire terminals. The residual current sensor is adapted to be mounted to a flat surface. The support holder is designed to be placed above the residual current sensor and to be connected to the flat surface. The support holder is further adapted for supporting the wire terminal block in a position above the residual current sensor. Conducting connection pins run from the conductors in the wire terminals through openings in the residual current sensor to the flat surface.