High-Voltage Connector Pre-Charge Resistor for Inrush Limiting
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Solution Overview
Problem
Connecting a high-voltage source to a capacitive load can cause an inrush of current, potentially damaging the load or switches/ connectors, necessitating the use of pre-charge circuits with relays that consume energy.
Innovation Solution
A high-voltage connector design that includes a pre-charge resistor connected in series with the conductors, limiting the inrush current and eliminating the need for energy-consuming relays by using mechanically actuated switches to control the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pre-charge circuit with relays is used to limit inrush current, then the capacitive load is protected from damage, but energy is consumed to operate the relays
Solution Approach 1:
The patent extracts the relay component from the pre-charge circuit and replaces it with a simple pre-charge resistor. This eliminates the energy-consuming electromagnetic actuation mechanism while retaining the current-limiting function, directly resolving the contradiction between protection reliability and energy consumption
Solution Approach 2:
The patent introduces a pre-charge resistor as an intermediary component between the high-voltage source and the capacitive load. This passive component limits inrush current through its resistance property without requiring active energy input, thereby protecting the load while avoiding relay energy consumption
2Reliability
If a pre-charge circuit with relays is used to limit inrush current, then the capacitive load is protected from damage, but the device complexity increases
Solution Approach 1:
The patent removes the relay component from the pre-charge circuit, simplifying the device structure. By replacing the complex electromagnetic relay mechanism with a simple resistive element, the patent reduces device complexity while maintaining the essential protection function
Solution Approach 2:
The patent employs a simple pre-charge resistor instead of a complex relay system. The resistor is a passive, inexpensive component that performs the current-limiting function without the mechanical or electromagnetic complexity of relays, thereby reducing overall device complexity
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
The solution effectively limits the inrush current to the capacitive load, preventing damage and reducing energy consumption by eliminating the need for relay-operating energy, thus providing a more efficient and reliable connection.
Implementation Method 1
a pre-charge resistor connected in series with the conductors, limiting the inrush current
Data Source
AI summary
Embodiments include a high-voltage connector having a first member electrically connected to a high-voltage source, the first member includes a first positive conductor and a second positive conductor and a first negative conductor and a second negative conductor and a second member electrically connected to a load that requires pre-charging, the second member includes a third positive conductor and a fourth positive conductor connected in parallel and a third negative conductor and a fourth negative conductor connected in parallel. The high-voltage connector also includes a pre-charge resistor disposed within one of the first member and the second member. The first member is configured to connect to the second member and to provide electrical power from the high-voltage source to the load.