High-Voltage Connector Assembly With Rotational Fastening Detection
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Solution Overview
Problem
Existing high-voltage connectors rely on visual inspection for fastener tightening, leading to inaccurate and inefficient checks, increasing the risk of connection failures and safety hazards.
Innovation Solution
A connector with a detection component that rotates between initial and detection positions based on the fastener's engagement with a high-voltage module, ensuring accurate verification of fastener tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If visual inspection is used to check fastener tightening, then the inspection process is simple, but the inspection accuracy is poor and efficiency is low
Solution Approach 1:
The patent replaces the manual visual inspection method with an automated detection component that uses mechanical interaction (rotation) to detect fastener tightening status. The detection component rotates between initial and detection positions, and its rotation is mechanically blocked or enabled by the fastener's engagement state, providing automated, accurate detection without relying on human visual judgment.
Solution Approach 2:
The fastener itself serves as the detection indicator. When the fastener is properly tightened, its position automatically enables the detection component to rotate to the detection position. The system uses the fastener's own state to indicate its tightening status, eliminating the need for separate inspection tools or methods.
2Productivity
If visual inspection is used to check fastener tightening, then no additional detection components are needed, but the inspection efficiency is low and errors are frequent
Solution Approach 1:
The detection component serves multiple functions: it detects fastener tightening status, provides visual feedback through its rotated position, and can prevent operation until proper tightening is achieved. By integrating this multi-functional component into the connector, the system improves inspection efficiency while keeping the overall structure compact and unified.
Solution Approach 2:
The patent merges the detection function with the existing connector structure. The detection component is integrated into the connector housing and works in conjunction with the fastener and high-voltage module, combining multiple functions (fastening, detection, indication) into a unified system rather than adding separate independent inspection equipment.
3Reliability
If the detection component is added to automatically detect fastener tightening, then inspection accuracy improves, but the device complexity increases
Solution Approach 1:
Instead of having the detection component actively measure or sense the fastener tightening, the patent inverts the approach: the fastener's position passively controls whether the detection component can rotate. The detection is achieved by the absence of mechanical interference rather than by active sensing, simplifying the detection mechanism while improving reliability.
Solution Approach 2:
The detection component acts as an intermediary between the fastener and the inspection process. It translates the mechanical state of the fastener (tightened or not) into a detectable rotational position, providing clear indication of the connection status without requiring complex sensing or measurement systems.
Data Source
AI summary
A connector includes a housing, a high-voltage module arranged in the housing, and a detection component rotatably installed on an exterior of the housing for detecting whether the high-voltage module has been fastened to the high-voltage mating module. The high-voltage module is adapted to be fastened to a high-voltage mating module of a mating connector. With the high-voltage module not fastened to the high-voltage mating module, the high-voltage module is in a position that interferes with the detection component, so that the detection component cannot be rotated from an initial position to a detection position. With the high-voltage module fastened to the high-voltage mating module, the high-voltage module is in a position that does not interfere with the detection component, allowing the detection component to be rotated from the initial position to the detection position.