High-Voltage Vehicle Component for Tool-Free Socket Replacement
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Solution Overview
Problem
Existing high-voltage system components in heavy vehicles are difficult to replace quickly and easily, leading to increased maintenance costs and complexity, as they often require workshop visits and alignment, which can result in faulty installations.
Innovation Solution
A high-voltage component with a cylindrical body, encapsulated electrical device, and circumferentially arranged conductive contact areas forming high-voltage terminals, along with a cap and fastening mechanism for secure socket installation, allowing for tool-free and alignment-free replacement, ensuring a plug-n-play functionality and secure seal against environmental degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional high-voltage system components are used, then the vehicle can operate with high-voltage systems, but the components are difficult to replace quickly and require workshop visits and alignment procedures
Solution Approach 1:
The high-voltage system is divided into modular components (contactors, fuses, pre-charge resistors) that are encapsulated in separate replaceable units. Each component can be independently removed and replaced without affecting other system parts, enabling quick swap-out operations without workshop visits or complex alignment procedures.
Solution Approach 2:
The component design incorporates dynamic fastening mechanisms that allow for tool-free attachment and detachment. The components transition from a secured state during operation to an easily removable state during maintenance, enabling rapid replacement by simply pulling the component out of its housing.
2Reliability
If traditional components requiring alignment are used, then electrical connections can be established, but the risk of faulty installation increases
Solution Approach 1:
The component housings feature asymmetric shapes with unique geometries that only fit into corresponding housings in one specific orientation. This asymmetric design eliminates the need for alignment during replacement, as the component can only be inserted correctly, ensuring reliable electrical connections and preventing faulty installations.
Solution Approach 2:
The component design includes self-aligning features where the component automatically positions itself correctly during insertion. The asymmetric housing geometry and integrated fastening mechanisms guide the component into the proper orientation without requiring manual alignment or adjustment by the installer.
3Productivity
If components are made easily replaceable without tools, then replacement speed increases, but the fastening mechanism must be simplified
Solution Approach 1:
The complex alignment and fastening procedures have been extracted from the replacement process entirely. The component design integrates simple snap-fit or bayonet-style fastening mechanisms that require no tools and no alignment, allowing the component to be removed and replaced by simple pulling and inserting motions.
Solution Approach 2:
The fastening mechanism is designed as a simple, low-cost disposable-style connection that prioritizes speed of replacement over reusability. The simple snap-fit or push-lock design allows for rapid replacement while maintaining sufficient mechanical strength for operational reliability.
Data Source
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AI summary
A component (100) for a high-voltage electric system of a vehicle, the component comprising: a body (102) having a circular cross section; an electrical device (104) encapsulated within the body; a first electrically conductive contact area (106) arranged circumferentially on the body and configured to form a first electrical connection (108) to the electrical device; a second electrically conductive contact area (110) arranged circumferentially on the body and configured to form a second electrical connection (112) to the electric device, the second electrically conductive contact area being separated from the first electrically conductive contact area in the axial direction of the body; a cap (114) attached to an end portion (118) of the body; and a fastening mechanism configured to secure the component in a socket.