Lever-Interlock Connector Sequencing for HVIL Safety Timing
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Solution Overview
Problem
Existing connector devices for high voltage and large current lack sufficient time intervals between the connection/disconnection of terminals for large current and HVILs, leading to potential safety hazards due to quick operations and unintended connections.
Innovation Solution
The connector device incorporates a lever with specific boss and groove configurations that allow for additional steps in the connection and disconnection process, including a rotation and sliding operation, along with a locking mechanism using spring pieces to ensure intentional operation and prevent unintended connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the connector device uses a simple lever operation for quick connection and disconnection, then the operation speed is improved, but the time interval between terminal connection/disconnection and HVIL connection/disconnection is insufficient, leading to safety hazards
Solution Approach 1:
The lever operation is segmented into two distinct phases: a rotation operation for connecting/disconnecting main terminals, and a sliding operation for connecting/disconnecting HVILs. This segmentation ensures that the operations occur in sequence with a sufficient time interval, preventing unintended connections while maintaining operational efficiency
Solution Approach 2:
The lever is designed to perform dynamic movements including rotation around a fulcrum and sliding along guide grooves. This dynamic mechanism allows the connector to transition between different operational states (connection/disconnection) in a controlled sequence, ensuring safety through the time interval between operations
2Reliability
If the connector device adds a locking mechanism using spring pieces, then the prevention of unintended connections is improved, but the device complexity increases
Solution Approach 1:
Spring pieces are used to provide automatic locking and unlocking functions. The spring pieces engage with grooves on the lever to lock it in place during rotation operation, and automatically release during sliding operation. This self-service mechanism prevents unintended connections without requiring additional complex control systems
Solution Approach 2:
The spring pieces act as intermediary elements between the lever and the housing, providing the locking function. These spring pieces engage with grooves to prevent unintended movement of the lever, thereby preventing unintended connections while adding minimal structural complexity
3Reliability
If the connector device requires additional steps in the connection and disconnection process, then the safety is improved by preventing unintended connections, but the ease of operation decreases
Solution Approach 1:
A single lever is designed to perform multiple functions: it rotates to connect/disconnect main terminals, slides to connect/disconnect HVILs, and engages with spring pieces for locking. This multi-functionality allows the connector to provide enhanced safety through additional operational steps while maintaining ease of use through a unified, intuitive lever mechanism
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A connector is provided with an interlock housing, to which an interlock terminal is attached, separately from a lever that performs connection and disconnection of main terminals with a mating connector, and a first spring piece is formed on the lever. Connection of HVILs is performed in a manner such that after the main terminals are mutually connected by rotating the lever from a first position to a second position, the lever is slid from the second position to a third position and the interlock housing is pushed down from an opening position to a closing position. When the lever is on the third position and the interlock housing is on the opening position, the first spring piece generates a first elastic restoring force. In a state applying no external force that slides the lever to the third position against the first elastic restoring force, the lever moves away from the third position and therefore, the interlock housing cannot be pushed down.