Electrical Interface Assembly Latching System for Secure Power Transfer
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Solution Overview
Problem
Conventional electrical interface assemblies in higher voltage vehicle systems face challenges such as increased security requirements, risk of electrical shocks, and high maintenance costs due to the need for secure fixation of components, which often results in single-use plastic components and prolonged servicing times.
Innovation Solution
An interface assembly with a latching system that includes an interface housing and an electrical contact element featuring latching noses and latches, allowing for secure fixation and easy release of the electrical contact element, reducing the need for single-use fixation means and minimizing servicing time, while also providing mechanical and electrical shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbar elements are permanently attached to the interface by pressing into plastic housing, then security measures and fixation firmness are improved, but device complexity and maintenance costs increase due to broken plastic components requiring replacement
Solution Approach 1:
The plastic housing is segmented into a reusable outer housing and a separate fixation element (latch mechanism). The latch can be removed and replaced independently without damaging the housing, allowing the housing to be reused while replacing only the fixation component.
Solution Approach 2:
The latch mechanism is designed as a disposable or replaceable component that can be removed and replaced without damaging the housing. After use, only the latch needs to be discarded or replaced, not the entire housing, reducing waste and maintenance costs.
2Reliability
If conventional fixation methods are used, then secure fixation is achieved, but loss of time increases due to breaking and replacing plastic housing parts during servicing
Solution Approach 1:
The fixation system transitions from a static permanent attachment to a dynamic reversible connection. The latch mechanism can be easily engaged and disengaged, allowing quick removal and replacement of the busbar element without time-consuming housing replacement.
Solution Approach 2:
The latch mechanism is pre-designed with features that facilitate easy engagement and disengagement. The busbar element comes pre-equipped with the latch, allowing for quick installation and removal during servicing operations.
3Power
If higher voltage systems are implemented, then power transmission capability is improved, but object-affected harmful factors increase due to electrical shock risk requiring electrostatic shielding
Solution Approach 1:
An electrostatic shield acts as an intermediary between the high-voltage busbar element and the external environment. This intermediate layer provides electrical isolation, allowing high power transmission while protecting against electrical shock risks.
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 latching system enables secure and reusable connection of electrical contact elements, reducing maintenance time and costs by eliminating the need for single-use fixation components and enhancing safety through secure and efficient electrical power transfer in higher voltage vehicle systems.
Implementation Method 1
The interface housing (100) includes at least two latches (130, 135). The electrical contact element (200) includes a busbar portion (210) and a plug-in portion (220), wherein the busbar portion includes at least two latching noses (211, 212). Each of the at least two latching noses is assigned to one of the at least two latches to block a release movement of the assigned latching nose upon mating of the electrical contact element and the interface housing.
Data Source
AI summary
An interface assembly includes an interface housing including a receiving portion arranged inside an interface cavity of the interface housing, for receiving an electrical contact element. The interface housing further includes at least two latches and an electrical contact element for transferring electrical power. The electrical contact element includes a busbar portion and a plug-in portion. The busbar portion includes at least two latching noses. Each of the at least two latching noses is assigned to one of the at least two latches to block a release movement of the assigned latching nose upon mating of the electrical contact element and the interface housing.