High-Voltage Connector Jogging Control for Short-Stroke Interlock Switching
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Solution Overview
Problem
Existing high-voltage connectors for new energy vehicles pose safety hazards due to the need for operators to perform live-line plugging and unplugging, which can result in arcing and risk to personal safety.
Innovation Solution
A high-voltage connector with a jogging control structure that allows for rapid switching on and off of the high-voltage inter-lock system, significantly reducing the distance of live-line plugging and unplugging and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pin terminal and socket terminal are used to form a high-voltage inter-lock loop, then the inter-lock function is achieved, but the plugging and unplugging distance is long causing live-line operation risks
Solution Approach 1:
The connector is divided into separate plug and socket components with distinct inter-lock terminals. The plug housing contains inter-lock terminals that engage with corresponding terminals in the socket housing, allowing the inter-lock function to be segmented from the main high-voltage connection. This segmentation enables the inter-lock to be established or disconnected independently over a short distance.
Solution Approach 2:
Dedicated inter-lock terminals act as intermediary elements between the plug and socket. These terminals specifically form the high-voltage inter-lock loop, serving as a mediator that enables the safety function without requiring the entire connector assembly to move through a long distance. The intermediary terminals facilitate the inter-lock function while minimizing the movement distance required.
2Object-affected harmful factors
If the high-voltage inter-lock loop is disconnected before unplugging, then operator safety is improved, but the control timing precision is insufficient
Solution Approach 1:
The inter-lock terminals are designed to be disconnected preliminarily before the main high-voltage connection is broken. During the unplugging process, the inter-lock terminals separate first, disconnecting the high-voltage inter-lock loop while the plug and socket remain connected. This preliminary action ensures the safety function is activated before the operator is exposed to live-line conditions.
Solution Approach 2:
The connector design enables rapid transition through the critical safety state. The inter-lock terminals are positioned and dimensioned to allow quick engagement and disengagement, rushing through the safety-critical moment efficiently. This minimizes the time the system spends in an unsafe state while ensuring the inter-lock function is properly executed.
3Speed
If the power terminal remains live during plugging, then connection speed is improved, but arcing risk increases endangering operator safety
Solution Approach 1:
The inter-lock terminals provide preliminary protection against harmful effects before the main connection is made. During plugging, the inter-lock terminals engage first, establishing the safety loop that prevents hazardous conditions. This preliminary anti-action ensures that even if the power terminal is live, the inter-lock function is already in place to protect against arcing and other harmful effects.
Solution Approach 2:
The high-voltage inter-lock loop serves as a protective cushion established beforehand. By ensuring the inter-lock is connected before the main power connection is made, the system creates a safety buffer that cushions against potential arcing and electrical hazards. This prior cushioning allows faster connection speeds while maintaining operator safety.
Data Source
AI summary
Disclosed in the present disclosure is a high-voltage connector for jogging control over high-voltage inter-lock, including a socket housing and a plug housing. A high-voltage male terminal and a high-voltage female terminal, which are electrically connectable to each other by being plugged with each other, are provided in the socket housing and the plug housing respectively. The high-voltage connector further includes a high-voltage inter-lock system, on which a jogging control structure is provided. The jogging control structure is configured to control, by means of a short-distance action, the high-voltage inter-lock system to be powered on or powered off, so as to control an electrical connectivity between the high-voltage male terminal and the high-voltage female terminal.