Interface Unit Type Coding for High-Voltage Plug Systems
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Solution Overview
Problem
The installation of high-voltage plug connections in electric vehicle on-board power systems is often complex and error-prone due to the lack of clear identification methods for matching cable-side and component-side interface units, leading to potential safety hazards and operational issues.
Innovation Solution
The implementation of a plug system with colored and/or physical type coding means on the housing of the cable-side interface unit allows for simple and reliable identification of corresponding component-side interface units, preventing incorrect connections through unique spatial and color profiles, and includes a method for checking cable harnesses using image data to detect manufacturing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional plug connections without type coding are used, then the device structure remains simple, but the installation becomes complex and error-prone
Solution Approach 1:
The patent applies color coding to the housing of the cable-side interface unit to provide visual identification of the interface type. Different colors or color patterns indicate different interface types, allowing installers to quickly identify the correct component without complex markings or documentation. This resolves the contradiction by adding minimal visual complexity (color application) while dramatically improving installation ease and error prevention.
Solution Approach 2:
The patent employs asymmetric physical coding features such as positioned protrusions, recesses, or shaped housing elements that create a unique spatial profile for each interface type. These asymmetric features ensure that only compatible interfaces can be physically connected, preventing incorrect installations. The asymmetric design adds minimal structural complexity while providing robust mechanical guidance and type identification.
2Reliability
If type coding means are added to identify interface units, then installation reliability improves, but manufacturing complexity increases
Solution Approach 1:
The color coding is applied as a surface treatment or coating on the housing, which can be integrated into the manufacturing process through conventional painting, anodizing, or molding with color inserts. This approach adds minimal manufacturing steps while providing reliable visual identification that prevents incorrect installations.
Solution Approach 2:
The asymmetric physical features are incorporated as integral parts of the housing structure during molding or machining. These features serve dual purposes: structural integrity and type identification. By combining these functions, the patent avoids additional manufacturing steps while ensuring installation reliability through physical compatibility constraints.
3Adaptability or versatility
If multiple interface units are used in the power system, then system functionality increases, but identification and matching difficulty increases
Solution Approach 1:
Each interface type in the multiplicity of interface units is assigned a distinct color or color pattern. This allows installers to quickly differentiate between various interface types (e.g., different voltage levels, connector types) without requiring detailed technical knowledge or reference materials. The color coding system scales easily to accommodate multiple interface types while maintaining simple identification.
Solution Approach 2:
Each interface type features a unique asymmetric spatial profile with specific protrusion patterns, recess locations, or housing shapes. This ensures that interface units can be visually and physically distinguished from one another, allowing installers to identify the correct component and ensure proper matching through physical compatibility. The asymmetric design naturally prevents incorrect connections even in complex systems with many interface types.
Data Source
AI summary
A cable-side interface unit for a plug system for transmitting electrical power in a high-voltage electrical system of a vehicle includes a housing configured to at least partially extend around one or more power contact parts of the cable-side interface unit and to fasten a cable to the cable-side interface unit. The interface unit also comprises colored and/or physical type coding means, which are arranged on an outer wall of the housing and make it possible to identify a certain component-side interface unit of the plug system from a plurality of different component-side interface units of the electrical system.