High-Current Releasable Connector Assembly Design
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Solution Overview
Problem
Current solutions for connecting high-current electrical devices, such as electrohydraulic motor-pump units, lack a compact, easily manageable, and detachable design, requiring permanent installation and leading to unnecessary replacement of both devices and cables during maintenance or fault situations.
Innovation Solution
A compact, detachable connection device for high currents, designed to be released and reconnected without damage, featuring a secure mechanical and electrical connection suitable for voltages from 12 V to 400 V, with a focus on reliability and ease of maintenance, including a connection device with a line connection part that can be inserted into a receptacle and secured with a screw or rivet, ensuring low contact resistance and compliance with environmental protection standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent cable connection is used inside electrical device, then reliable electrical connection is achieved, but maintenance effort increases and device replacement becomes necessary
Solution Approach 1:
The cable connection is segmented into two separate parts: a permanent connection inside the electrical device and a detachable connector on the cable. This allows the cable to be replaced independently without replacing the entire electrical device, while maintaining reliable electrical connection through the permanent internal attachment.
Solution Approach 2:
The detachable connector is extracted from the electrical device and placed on the cable side. This extraction allows the cable to be easily removed and replaced while leaving the electrical device intact, reducing maintenance effort while preserving connection reliability through the permanent internal mounting structure.
2Ease of repair
If detachable connector is designed for high currents, then cable replacement becomes possible, but contact resistance increases
Solution Approach 1:
The connection system is divided into a permanent internal connection point and a detachable external connector. The permanent internal connection ensures low contact resistance by directly attaching the cable connector to the electrical device terminal, while the detachable nature allows easy cable replacement.
Solution Approach 2:
The cable connector is pre-designed and pre-attached to the cable assembly before installation. This preliminary preparation ensures that when the cable is connected to the electrical device, the contact surfaces are already optimized for low resistance, eliminating the need for field adjustments that could increase contact resistance.
3Volume of moving object
If compact connector design is implemented, then space is saved, but contact area for high currents is reduced
Solution Approach 1:
The connector design transitions from a two-dimensional surface contact to a three-dimensional multi-contact structure. Multiple contact points are arranged in parallel, effectively increasing the total contact area without proportionally increasing the connector's external dimensions. This allows compact packaging while maintaining high current-carrying capacity through the cumulative effect of multiple contact surfaces.
Data Source
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AI summary
The invention relates to a high-current connection device (300) for detachably connecting an electrified device (20) to a connecting conductor (203; 203a, 203b), a corresponding connection device (101), and a corresponding line connection device (201), wherein a connection part (101) can be attached to a housing part (33) of the E-device (20), and a connecting conductor (103; 103a, 103b) extends through the connection part (101) into the interior (35) of the housing (30) and can be connected at one end (103-1; 103-1a, 103-1b) therein to the power connection (25; 25a, 25b), and at another end (103-2; 103-2a, 103-2b) to a first contact surface (104; 104a, 104b); the connecting conductor (203; 203a, 203b) is guided through the line connection part (201) and the line connection part (201) is inserted at least partially into a receptacle (105) on the connection part (101) in such a way that the first contact surface (104;104a, 104b) a second contact surface (204; 204a, 204b) of the connecting current conductor (203; 203a, 203b) contacts; and a detachable first connecting element (207; 207a, 207b) extends through the conductor connection part (201) inserted into the connection part (101), through the second contact surface (204; 204a, 204b) and through the first contact surface (104; 104a, 104b) and interacts with a first connecting element (107; 107a, 107b) integrated into the connection part (101) in such a way that the first contact surface (104; 104a, 104b) and the second contact surface (204; 204a, 204b) are pressed together and the conductor connection part (201) is detachably attached to the connection part (101).