Generator Set Connection Module for Vibration-Safe Plug-In Wiring
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing generator sets face challenges with complex and error-prone wiring connections due to varying engine drives, requiring meticulous and time-consuming installation, and are prone to vibration-induced unsecurement, leading to potential malfunctions and safety risks.
Innovation Solution
An electrical connection module with a unified casing integrating power supply, protection, and diagnostic functions, featuring connectors for harnesses and control modules, allowing plug-and-play connections and reducing the need for individual adaptation to each engine configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard off-the-shelf fuse boxes are used for electrical protection, then large production runs are well adapted, but they are not suitable for generator sets subject to vibration, heat and splashing
Solution Approach 1:
The electrical connection module integrates multiple functions (electrical protection, connection, and adaptation) into a single universal component that can be applied across different generator set configurations, eliminating the need for separate standard fuse boxes that fail under operational conditions
2Reliability
If wiring ends are stripped and screwed to terminals in standard fuse boxes, then electrical protection is provided, but installation is complex and time-consuming
Solution Approach 1:
The electrical connection module comes pre-configured with integrated connectors and electrical protection elements already in place, eliminating the need for现场 stripping and screwing operations. The module is prepared in advance for immediate installation
Solution Approach 2:
The patent replaces the mechanical screwing connection system with a plug-and-play connector system that provides electrical protection without requiring manual stripping and fastening operations
3Reliability
If wiring is connected by screwing to terminals, then electrical connections are established, but vibration causes wiring to become unsecured
Solution Approach 1:
The patent replaces vibration-prone mechanical screw connections with a secure plug-and-play connector system that maintains electrical connection stability under vibrational conditions through integrated locking or retention mechanisms
4Adaptability or versatility
If several control modules are implemented for large multi-cylinder engines, then each sub-set of cylinders is managed, but it is not easy for operators to control the whole system
Solution Approach 1:
The electrical connection module serves as a universal interface that consolidates control signals and power distribution for multiple control modules, providing a single point of interaction that simplifies operator control while maintaining the functional separation needed for managing different cylinder sub-sets
Data Source
AI summary
The invention relates especially to an electrical connection module for a generator set comprising an alternator connected to a heat engine, formed by at least one sub-set of cylinders, said module comprising a casing housing a printed circuit supporting: electric power supply terminals for said printed circuit; a first connector of an electrical harness allowing, in each sub-set of cylinders, connection of at least one device for measuring and controlling parameters of said sub-set of cylinders to a control module of said sub-set of cylinders; second connectors for electrical protection members of said electrical harness; and a third connector for diagnosing the operating state of each control module.