Integrated Quick-Disconnect Connector for Safe UPS Battery Switching
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Solution Overview
Problem
Existing connectors for connecting UPSs to external battery packs lack a quick-disconnect mechanism, pose risks of electrical discharge during connection and disconnection, require additional circuit breakers for safety, and do not meet high voltage and current requirements, leading to space and cost constraints.
Innovation Solution
A quick disconnect connector assembly with a plug and receptacle, featuring a slide and latches that allow tool-free connection and disconnection, ensuring safe voltage interruption and compliance with industry standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If connectors are screwed into the chassis to secure connection, then connection stability is improved, but connection time increases and quick disconnect capability is lost
Solution Approach 1:
The connector is divided into a fixed portion (receptacle in the UPS) and a movable portion (plug with quick disconnect mechanism). The plug includes a body, contact members, and a disconnect mechanism that can be quickly actuated without tools, separating the secure mounting function from the quick connection/disconnection function.
Solution Approach 2:
The connector incorporates a dynamic quick disconnect mechanism that allows the plug to be rapidly connected and disconnected from the receptacle. The disconnect mechanism includes movable components that enable tool-free operation, transforming the static screwed connection into a dynamic quick-connect system.
2Reliability
If circuit breakers are added to protect against electrical discharge, then safety is improved, but device complexity and cost increase
Solution Approach 1:
The connector includes built-in contact members and a disconnect mechanism that are pre-configured to safely establish and break electrical connections. The design incorporates inherent safety features such as contact protection and controlled disconnection sequences, eliminating the need for additional circuit breakers.
Solution Approach 2:
The connector performs its own safety functions through integrated design elements. The contact members are positioned and protected within the connector body, and the disconnect mechanism automatically manages the electrical connection status, making the system self-protecting without external circuit breakers.
3Stability of the object's composition
If overmolded cables with screws are used to secure connectors, then connection security is improved, but ease of operation deteriorates due to tool requirement
Solution Approach 1:
The screw fastening mechanism is extracted and replaced with a tool-free quick disconnect mechanism. The plug and receptacle are designed with complementary features that provide secure connection through mechanical engagement without requiring screws or tools, maintaining connection security while dramatically improving ease of operation.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~4
AI summary
A cable connector includes a slide coupled to a spring to bias the slide from a retracted position to an extended position and at least one latch coupled to the slide. The slide, when in the extended position, is configured to rotate the at least one latch to secure the at least one latch, and when in the retracted position, is configured to rotate the at least one latch in an opposite direction to release the at least one latch. The slide is configured to engage a contact switch when securing the at least one latch.