High-Voltage Connector Spring Contact Latching Mechanism
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Solution Overview
Problem
Existing connecting apparatuses for high-voltage current transmission in the motor vehicle sector require precise orientation of connection elements, leading to high fitting costs and complexity, particularly in automated manufacturing processes.
Innovation Solution
A connecting apparatus featuring a ring contact element and two spring contact elements with a shock protection mechanism, allowing for simplified fitting and secure latching, where the spring contact elements are recessed in the non-fitted state and project in the fitted state, ensuring precise contact and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection elements are precisely oriented to ensure reliable connection, then connection reliability is improved, but fitting complexity and cost increase
Solution Approach 1:
The patent employs asymmetric design in the ring contact element and spring contact elements, where the ring contact element has a specific orientation with its opening direction and the spring contact elements are positioned at specific angles (e.g., 120 degrees apart). This asymmetric configuration ensures reliable electrical contact while providing inherent orientation guidance that simplifies the fitting process, as the components can only be assembled in the correct orientation.
Solution Approach 2:
The ring contact element is designed with a circular or annular shape, providing rotational symmetry in its overall form while maintaining asymmetric contact points. This curved geometry allows for tolerance compensation in radial directions while maintaining precise contact at specific angular positions, thereby ensuring reliable connection without requiring extremely precise orientation during assembly.
2Manufacturing precision
If precise orientation of connection elements is required, then contact precision is improved, but manufacturing cost increases
Solution Approach 1:
The electrical contact system is segmented into a ring contact element with multiple discrete spring contact elements positioned at specific intervals around the ring. This segmentation allows each spring contact element to be independently manufactured and positioned, enabling precise contact geometry to be achieved through modular assembly rather than requiring high-precision machining of the entire component, thereby reducing manufacturing cost while maintaining contact precision.
Solution Approach 2:
The patent utilizes elastic deformation parameters of the spring contact elements to achieve precise contact. The spring contact elements are designed with specific material properties and geometric parameters (wire diameter, coil diameter, number of turns) that allow them to exert controlled contact force and compensate for manufacturing tolerances. This parameter optimization enables reliable electrical contact without requiring extremely tight manufacturing tolerances, thus reducing manufacturing cost.
3Productivity
If simple fitting process is implemented, then productivity is improved, but connection reliability may deteriorate
Solution Approach 1:
The spring contact elements are designed as dynamic components that can elastically deform during the fitting process. As the ring contact element is inserted, the spring contact elements automatically compress and then rebound to establish reliable electrical contact. This dynamic behavior ensures that even with simplified fitting procedures and moderate orientation precision, the spring action compensates for any gaps or misalignments, maintaining connection reliability while enabling high-speed automated assembly.
Solution Approach 2:
The spring contact elements possess self-adjusting capability through their elastic properties. During assembly, they automatically position themselves to make contact with the ring contact element at the correct locations, and they continuously maintain contact pressure through their spring force. This self-service mechanism ensures reliable electrical connection without requiring complex external positioning or adjustment mechanisms, thereby maintaining high productivity while ensuring connection reliability.
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
This design simplifies the fitting process, reduces production costs, and ensures reliable latching and shielding, while maintaining secure contact connections for high-voltage current transmission.
Implementation Method 1
The spring contact element is arranged in a displaceable manner in a housing part in such a way that the spring contact element is arranged so as to be recessed in relation to a housing surface in the non-fitted state, and is arranged so as to project in relation to the housing surface in the fitted state
Data Source
AI summary
A connecting apparatus for transmitting high-voltage current in a motor vehicle has a first connection element (4), a second connection element (6), a shielding housing (12) and fasteners (8, 10). The first connection element (4) has a housing (20) having a first insulating housing (21), a first contact (18) connected electrically to an internal conductor (16) of a cable (14), and a shielding arrangement (28) connected to a shield (30) of the cable (14). The shielding arrangement (28) is connected to the shielding housing (12) by a shielding part (32). The second connection element (6) has a second housing (41) having a second insulating housing part (42) with a second contact element (46) connected to a current line element. A weak-current contact arrangement creates a control circuit, and has a ring contact (52) and two spring contacts (60, 62).