HVIL Connector Spring Mechanism for Geometric Tolerance Independence
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Solution Overview
Problem
High-voltage interlock systems in vehicles face challenges in ensuring secure and reliable transmission of high-voltage current while maintaining independence from geometric error tolerances and ensuring user safety during connection and disconnection.
Innovation Solution
A high-voltage interlock system with kinematic lagging, where power contacts establish contact before HVIL contacts, utilizing spring elements to ensure secure and robust connections, and a method involving a first and second connector portion with spring elements and HVIL contact elements that deform to establish and maintain HV current transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If HVIL contact elements are designed to contact simultaneously with power contacts, then connection reliability is improved, but the system becomes sensitive to geometric error tolerances
Solution Approach 1:
The spring element is pre-loaded to automatically close the HVIL contact elements after power contact elements are connected. This preliminary mechanical action ensures HVIL contact establishment without requiring precise geometric alignment, as the spring force overcomes minor manufacturing tolerances and positional variations in the connector components.
2Reliability
If spring element is used to close HVIL contact elements, then independence from geometric errors is achieved, but contact-making time is delayed
Solution Approach 1:
The spring element provides dynamic response to the connection process. As the connector components are brought together, the spring element dynamically adjusts its compression and releases stored mechanical energy to rapidly close the HVIL contact elements. This dynamic mechanism compensates for the time delay by ensuring rapid contact establishment once the power contacts are connected, while maintaining independence from geometric errors through the spring's mechanical compliance.
3Object-affected harmful factors
If HVIL contact elements are designed to contact before power contacts, then safety is improved, but incorrect connection sequence may cause hazards
Solution Approach 1:
The spring element acts as a mechanical intermediary that couples the power contact connection sequence to the HVIL contact closure. The spring is mechanically linked to the power contact elements, so it can only be activated after the power contacts are properly connected. This intermediary mechanism ensures that HVIL contacts are closed in the correct sequence (after power contacts), preventing electrical hazards while maintaining user safety through automatic interlocking.
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 system operates independently of geometric errors, ensures robust and reliable HV current transmission, and provides user safety by delaying disconnection to prevent electrical hazards.
Implementation Method 1
at least one first spring element which, in the plugged state of the HV connector, is deformed in such a way that the first HVIL contact element makes contact with the second HVIL contact element
Data Source
AI summary
The present invention relates to a HVIL system for a HV connector, in particular in a motor vehicle, which HV connector is configured to transmit HV current from the HV connector to a further component, wherein the HVIL system has a first HVIL contact element and a second HVIL contact element, wherein, in a non-plugged state of the HV connector, the first HVIL contact element is spaced apart from the second HVIL contact element by at least one first spring element; and wherein, in a plugged state of the HV connector, the first spring element is deformed in such a way that the first HVIL contact element makes contact with the second HVIL contact element in such a way that the HVIL system ensures that HV current is transmitted from the HV connector to the further component if the connection between the HV connector and the further component is secure. The present invention furthermore relates to a method for establishing a HV connection.