Insulated Rotary Coupling Device for Electric Vehicle Battery Tools
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Solution Overview
Problem
Existing electrically insulated coupling devices do not provide adequate protection against high electric fields and are not effective in preventing electrical damage to equipment when working with live components.
Innovation Solution
An electrically insulating rotary coupling device with a molded plastic intermediate member featuring a transverse electrically insulating partition and machined steel heads, providing reliable insulation against electric arcs and high dielectric strength, along with an adapter for tools with an outer insulating coating for enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a non-metallic transmission member is used between coupling heads, then electrical insulation is provided, but protection against high electric fields and electric arcs is insufficient
Solution Approach 1:
The intermediate member is segmented into multiple insulating partitions that divide the internal space into separate compartments. This segmentation creates multiple insulation barriers, preventing electric arcs from bridging across the coupling heads while maintaining mechanical torque transmission capability.
Solution Approach 2:
The intermediate member acts as an intermediary element between the first and second coupling heads. It provides electrical insulation through its non-metallic construction and insulating partitions, while still enabling mechanical coupling and torque transmission, thus mediating both electrical and mechanical functions.
2Object-affected harmful factors
If insulated tools are used to work on live components, then operator safety is improved, but equipment upstream remains vulnerable to electrical damage
Solution Approach 1:
The coupling device serves as an intermediary protective element between the insulated tool and the equipment. The dual insulation system (outer coating on the tool plus internal partitions in the coupling device) creates multiple barriers that protect upstream equipment from electrical damage while maintaining operator safety.
Solution Approach 2:
The coupling device incorporates insulation partitions and spacing features that create protective barriers before electrical hazards can reach the equipment. This preemptive insulation design cushions the equipment against potential electrical surges or arcs from live components.
3Object-affected harmful factors
If a transverse insulating partition is added to the intermediate member, then protection against electric arcs is improved, but device complexity increases
Solution Approach 1:
The insulating partitions are merged into the intermediate member as an integrated structure rather than separate components. The partitions are formed as part of the molded intermediate member, combining mechanical transmission and electrical insulation functions into a single unified component, thus reducing overall device complexity.
Solution Approach 2:
The intermediate member utilizes composite construction with insulating material integrated into the structural component. This allows the same element to provide both mechanical torque transmission and electrical arc resistance without requiring additional separate parts.
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 isolates the coupling heads from each other and the operator, preventing electric shocks and equipment damage, while being compact and cost-effective for use in environments with voltages up to 1500 volts.
Implementation Method 1
the intermediate member is a molded part made of a plastic material with high dielectric strength
Implementation Method 2
The invention provides reliable insulation against electric arcs
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The coupling device (10) comprises a first head (12) with at least one male part (26); a second head (14) with at least one associated female part (42); and an intermediate member (16) electrically insulating said male and female parts. The intermediate member (16) comprises transverse partitioning (62) arranged across the entire joint via which the first and second heads (12; 14) are assembled. Application to an adaptor for a tool used for fitting or servicing batteries that power electric vehicles.