Lockable Connector for High-Voltage EV Safety
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Solution Overview
Problem
High-voltage plug connections in electric vehicles pose safety risks during maintenance due to the potential for accidental contact with live electrical components, and existing solutions lack sufficient protection against unauthorized access or disconnection.
Innovation Solution
A contact system with a locking element that secures the plug to the mating connector using a resilient mechanism, such as a wedge-shaped or spring-loaded design, and includes a locking pin and perforated edge to prevent unauthorized removal, while also providing a secure fit against vibrations and ensuring safe disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plug connection is used for high-voltage applications, then electrical connectivity is achieved, but safety risks arise during maintenance due to potential accidental contact with live components
Solution Approach 1:
The locking element is pushed onto the connector collar before the plug connection is made, establishing a mechanical lock in advance that prevents accidental disconnection during maintenance operations. This preliminary mechanical securing action occurs before electrical engagement, ensuring safety is established prior to full system operation.
Solution Approach 2:
The locking element acts as an intermediary mechanical component between the connector and mating connector, providing a physical barrier and locking mechanism that prevents direct access to live electrical components. This intermediate locking structure mediates between the need for electrical connectivity and the need for safety during maintenance.
2Stability of the object's composition
If a locking device is provided to prevent accidental disconnection, then connection stability is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is segmented into distinct functional components: a locking element that can be pushed onto the connector collar, a connector collar with specific geometric features, and a mating connector with corresponding engagement features. This segmentation allows each component to perform its specific function independently while maintaining overall system simplicity.
Solution Approach 2:
Instead of using a complex active locking mechanism that requires actuation, the design inverts the approach by using a passive locking element that relies on the natural geometry of the connector collar and mating connector. The locking action occurs automatically when the locking element is pushed onto the collar, eliminating the need for additional actuators or control systems.
3Reliability
If a resilient pressing mechanism is used to secure the connector against vibrations, then connection reliability under vibration is improved, but manufacturing complexity increases
Solution Approach 1:
The locking element utilizes resilient material properties and geometric parameters to create a pressing effect that adapts to vibration conditions. By changing the material parameters (resilience) and geometric parameters (wedge shape, curvature radius), the mechanism automatically adjusts the pressing force to maintain reliable connection under varying vibration conditions without requiring active control.
Solution Approach 2:
The resilient locking element provides self-service by automatically adjusting its pressing force in response to vibration-induced movements. The elastic deformation of the locking element creates a self-regulating mechanism that maintains optimal contact pressure without external intervention, simplifying the manufacturing process while ensuring vibration resistance.
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 solution effectively secures high-voltage connections during maintenance, preventing accidental disconnection and unauthorized access, thereby enhancing safety and reliability by ensuring the plug remains locked until intended release, thus reducing the risk of electrical hazards.
Implementation Method 1
The locking element can be wedge-shaped, for example, along a planar extension, so that a pressing effect can be generated by being supported against the projection area when it is pushed in and locked. The locking element can, for example, have a curved leaf spring for resilient pressing, which is designed and arranged to be resiliently supported against the at least one projection region when the locking element is pushed onto the plug collar.
Data Source
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AI summary
The invention relates to a contact system. The contact system comprises at least one plug and at least one mating plug. The plug has at least one electrically conductive contact, and the mating plug has at least one electrically conductive mating contact. The contact system includes a locking element configured to be slid along a translational axis onto a plug collar of the plug and to secure the plug against detachment from the mating plug. The mating plug has a projecting area extending in the direction of the flat extension of the plug collar, which is arranged and configured to at least partially engage or engage behind the locking element and hold it against the plug collar.