HV Interlock Connector Assembly for Full-Engagement Safety
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Solution Overview
Problem
Conventional power distribution components in motor vehicles face challenges such as space constraints, harsh operating conditions, and high failure rates due to incorrect installation and dislodgment, leading to significant repair and warranty costs.
Innovation Solution
A connector system with an interlock assembly that includes a high voltage interlock system, featuring a spring member with centering means to ensure proper positioning and prevent electrical current flow until full engagement, reducing the risk of connector failure and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power distribution components are used without interlock systems, then the connector system is simpler and easier to manufacture, but electrical current may flow before full engagement leading to component failure and safety hazards
Solution Approach 1:
The interlock system performs preliminary action by mechanically preventing electrical contact until the connector is fully engaged. The interlock member blocks the electrical contact member from making contact with the electrical contact recess until the housing is completely inserted into the receptacle, ensuring safe engagement sequence.
Solution Approach 2:
The interlock member acts as an intermediary between the housing and the electrical contact member. It mediates the engagement process by physically blocking the electrical contact member until the housing reaches its fully inserted position, thereby controlling the sequence of engagement.
2Reliability
If connectors are designed without dislodgment prevention features, then manufacturing and assembly are simpler, but connectors may become dislodged in harsh operating conditions leading to failure
Solution Approach 1:
The connector system is segmented into distinct functional components: the housing, the interlock member, the electrical contact member, and the retainer. This segmentation allows each component to perform its specific function independently while simplifying manufacturing and assembly processes.
Solution Approach 2:
The retainer is pre-positioned in the housing to automatically engage with the connector upon insertion. This preliminary positioning ensures that once the connector is inserted, it is immediately secured against dislodgment without requiring additional assembly steps.
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 connector system effectively prevents electrical current from flowing until the connector is fully engaged, reducing failure rates and extending the lifespan of electrical components, thereby lowering repair and warranty costs.
Implementation Method 1
an innovative spring member with centering means that ensures proper relative positioning of the components of the connector system
Data Source
AI summary
The connector system is configured for use in a power distribution system of a motor vehicle, and wherein the connector system includes a female housing, female terminal assembly, and a female interlock (FIL) assembly. The female housing having an arrangement of side walls that define a receptacle that is configured to receive the female terminal assembly. The female interlock (FIL) assembly positioned within the female terminal assembly that resides within the receptacle of the female housing to define a fully assembled female state SFAF, whereby the FIL assembly is configured to be coupled to an interlock circuit that prevents electrical current from flowing through the female terminal assembly prior to connection of the female terminal assembly to a male terminal assembly.