Interlock Pin Vibration Resistance Design
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Solution Overview
Problem
High-voltage electric vehicles face issues with arc generation and structural instability due to vibrations when disconnecting connectors from high-voltage batteries, which can damage components and pose fire risks, and existing interlock pins lack sufficient vibration resistance.
Innovation Solution
An interlock pin design featuring a pin portion with electrical input/output pins and a body portion that includes grooves and protruding portions for enhanced vibration resistance, coupled with a battery management system that allows for safe electrical disconnection and structural stability, using a synthetic resin for fixation and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an interlock pin is used to prevent arc generation during connector disconnection, then electrical safety is improved, but the structural stability of the interlock pin deteriorates due to vibrations in the vehicle environment
Solution Approach 1:
The interlock pin is divided into distinct functional segments: a pin portion for electrical contact and a body portion for mechanical support. This segmentation allows each part to be optimized independently - the pin portion for electrical connectivity and the body portion for vibration resistance through features like grooves and protruding portions.
Solution Approach 2:
The body portion includes pre-designed vibration-resistant features (grooves and protruding portions) that cushion and absorb vibrational forces before they can affect the pin portion. This beforehand cushioning protects the electrical contacts from vibration-induced instability.
2Stability of the object's composition
If the interlock pin is designed with vibration-resistant features, then structural stability is improved, but the complexity of the device increases
Solution Approach 1:
The vibration-resistant features (grooves and protruding portions) are merged directly into the body portion of the interlock pin, combining multiple functions - mechanical support, vibration resistance, and structural integrity - into a single integrated component rather than adding separate elements.
Solution Approach 2:
The body portion serves multiple functions simultaneously: it provides mechanical support for the pin portion, resists vibrations through integrated features, and maintains the overall structural stability of the interlock assembly, reducing the need for additional specialized components.
3Device complexity
If the physical contact point between the pin portion and body portion is close to the pins, then the interlock pin structure is simplified, but vibration resistance deteriorates
Solution Approach 1:
The design extends the body portion further along the first direction (axial dimension) beyond the physical contact point, creating a dimensional buffer zone. This extension in the axial direction provides vibration resistance without complicating the radial or lateral structure of the interlock pin.
Data Source
AI summary
An interlock pin includes a pin portion and a body portion. The pin portion includes a plurality of electrical input/output pins. The body portion accommodates at least a portion of the pin portion. In the interlock pin, the pins of the pin portion extend from the body portion along a first direction and, a furthest point from one end of the body portion is further along the first direction than a physical contact point between the body portion and the pin portion.