Insulated Feed-Through Connector for Roof-Mounted Charging Rails
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Solution Overview
Problem
There is a need for a reliable connection system on locomotives to link high voltage battery packs located inside the locomotive to external electrical charging systems, ensuring efficient and safe power transfer.
Innovation Solution
A feed-through electrical connector is designed to connect the battery to a charging rail, featuring a stud made of conductive material, insulation for roof attachment, a ring terminal for battery connection, and a fitting for charging rail connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a feed-through electrical connector is used to connect battery to external charging system, then electrical connection reliability is improved, but device complexity increases due to insulation and mounting requirements
Solution Approach 1:
The patent combines multiple functions into a single feed-through electrical connector: electrical conduction, insulation, structural support, and weather sealing. The connector integrates a conductive element, insulating material, mounting features, and sealing mechanisms into one unified component that passes through the vehicle roof, eliminating the need for separate components and reducing overall system complexity while maintaining reliability.
Solution Approach 2:
The feed-through electrical connector acts as an intermediary component between the internal battery system and external charging infrastructure. It provides a controlled interface that enables electrical power transfer while maintaining vehicle integrity, offering mounting attachment points for securing the connector to the roof and sealing mechanisms to prevent environmental contamination of internal components.
2Reliability
If insulation is added around the conductive stud, then electrical safety is improved, but manufacturing complexity increases
Solution Approach 1:
The connector employs composite construction combining conductive materials (for electrical conduction) with insulating materials (for electrical safety) in a single integrated structure. The insulating material surrounds the conductive stud, creating distinct functional zones within one component that provides both electrical conductivity where needed and insulation where required for safety.
3Stability of the object's composition
If a secure mounting system is implemented, then connection stability is improved, but installation difficulty increases
Solution Approach 1:
The connector includes pre-formed mounting attachment points and sealing structures that are integrated into the connector body during manufacturing. These pre-prepared features enable straightforward installation by allowing direct attachment to the vehicle roof without requiring separate mounting operations or complex assembly steps, thus maintaining connection stability while simplifying installation.
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 provides a secure, weather-resistant, and efficient electrical connection between the battery and charging system, eliminating the need for additional cables and enabling universal docking for charging.
Implementation Method 1
an insulation disposed about the stud, the insulation configured to be placed in a hole of the roof of the locomotive and attached to the roof of the locomotive
Implementation Method 2
a stud having a bottom end and a top end, the stud being formed from an electrically conductive material
Data Source
AI summary
A feed-through electrical connector configured to connect electrical components from an exterior to an interior of a vehicle, including a stud having a bottom end and a top end, the stud being formed from an electrically conductive material, an insulation disposed about the stud, the insulation configured to be placed in a hole of a roof of the vehicle and connect to the roof of the vehicle, a ring terminal connection disposed at the bottom end of the stud, the ring terminal connection being configured to connect the stud to electrical components on the interior of the vehicle, and a fitting disposed at the top end of the stud, the fitting configured to connect the stud to a slotted charging rail on the exterior of the vehicle.