High-Voltage Vehicle Connector with Relay-Driven Safe Replacement
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Solution Overview
Problem
Existing high-voltage systems in vehicles face challenges in providing components that are both reliable and easily replaceable without requiring workshop visits, with existing solutions often increasing cost and design complexity.
Innovation Solution
A component comprising a hollow body with circumferentially arranged contacts and an axially movable connector element controlled by an electromagnetic relay, allowing for fast and tool-free installation and removal, with secure and reliable electrical connections through flanges and insulating sheaths, and optional multi-stage actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If high-voltage components are made replaceable for easy serviceability, then ease of repair is improved, but reliability may worsen due to potential faulty installation
Solution Approach 1:
The connector element features an asymmetric design where the contact surfaces are positioned at specific axial locations that do not align with the external contacts in the disconnected state. This asymmetry ensures that proper alignment is achieved only in the correct inserted orientation, preventing faulty installation while maintaining easy replaceability
Solution Approach 2:
The component design incorporates self-aligning features where the connector element automatically positions itself correctly upon insertion. The internal structure guides the connector to the proper alignment with external contacts, eliminating the need for manual alignment procedures and reducing installation errors
2Ease of repair
If component design is simplified for fast replacement, then ease of repair is improved, but device complexity may worsen due to additional safety mechanisms
Solution Approach 1:
The patent combines multiple functions into the connector element: electrical connection, mechanical coupling, and alignment guidance are all integrated into a single component. This merging reduces the overall system complexity while enabling fast replacement, as the connector element performs multiple roles simultaneously rather than requiring separate mechanisms for each function
Solution Approach 2:
The component is divided into modular segments: a replaceable connector element and a stationary housing with external contacts. This segmentation allows the connector element to be easily removed and replaced without affecting other components, simplifying the replacement process while maintaining necessary safety features within the modular 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
Enables safe, fast, and easy replacement of high-voltage components with reduced risk of faulty installation, secure electrical connections, and simplified maintenance, enhancing serviceability and reliability.
Implementation Method 1
an electromagnetic relay arranged to control axial movement of the connector element, wherein the relay is configured so that actuation of the relay results in an axial movement of the connector element to form an electrical connection between the first contact and the second contact
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A component (100) for a high-voltage electric system of a vehicle, the component comprising: a hollow body (102) having a circular cross section; a first contact (106) arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body; a second contact (110) arranged circumferentially in the body and configured to be externally exposed and to reach an interior of the body, the second contact being separated from the first contact in the axial direction of the body; an axially movable connector element (200) arranged within the body; and an electromagnetic relay (202) arranged to control axial movement of the connector element, wherein the relay is configured so that actuation of the relay results in an axial movement of the connector element to form an electrical connection between the first contact and the second contact.