Locking Socket Connection for Fast High-Current Mating
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Solution Overview
Problem
Existing electrical connection devices for high current power transmission in large power systems, such as electric vehicle charging systems, are cumbersome and costly due to complex mating and un-mating processes, hindering flexible layout adjustments and increasing installation and maintenance times.
Innovation Solution
An electrical connection device featuring a housing, a connecting socket, a conducting contact element, an elastic element, and an engaging element, where the engaging element inserts into a notch of an electrical connecting terminal, allowing the device to be locked and unlocked by moving the housing relative to the terminal along the lengthwise direction of the socket, facilitated by an elastic element that compresses to secure the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connection devices are used for high current power transmission, then reliable electrical connection is achieved, but the mating and un-mating process becomes cumbersome and time-consuming
Solution Approach 1:
The device is divided into distinct functional components: a housing structure, a connecting socket with mating portion, and a separate engaging element. This segmentation allows the engaging element to be independently actuated to control the locking mechanism, enabling quick mating and un-mating operations while maintaining reliable electrical connection through the dedicated connecting socket
Solution Approach 2:
The engaging element is designed to be movable relative to the housing, transitioning between engaged and disengaged states. This dynamic mechanism allows the connection device to quickly switch between locked and unlocked states, significantly reducing the time required for installation and maintenance while preserving connection reliability through positive engagement
2Reliability
If traditional electrical connection devices are used, then stable power transmission is achieved, but the layout adjustment flexibility is reduced
Solution Approach 1:
The movable engaging element enables dynamic reconfiguration of the electrical connection system. Connections can be quickly established and disconnected without complex tools or procedures, allowing flexible layout adjustments in electric vehicle charging systems while maintaining stable power transmission through the robust connecting socket design
3Reliability
If complex locking mechanisms are used to secure high current connections, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The locking function is separated from the electrical connection function. The engaging element handles the mechanical locking task independently, while the connecting socket maintains the electrical connection. This segmentation simplifies each component's design and reduces overall device complexity while ensuring reliable and secure high current connections
Solution Approach 2:
The engaging element is extracted as a distinct functional component from the housing, dedicated solely to the locking/unlocking operation. This extraction simplifies the housing design and allows the engaging element to be independently actuated, reducing overall device complexity while maintaining connection security
4Reliability
If traditional mating processes are used, then adequate electrical contact is achieved, but installation and maintenance costs increase
Solution Approach 1:
The dynamic engaging element enables rapid mating and un-mating operations without requiring complex tools or specialized procedures. This reduces installation and maintenance time, thereby lowering labor costs, while the connecting socket ensures adequate electrical contact quality for high current power transmission
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
This design simplifies the mating and assembly process, reducing installation and maintenance time and costs by enabling efficient locking and unlocking mechanisms.
Implementation Method 1
the elastic element is configured to be compressed along a lengthwise direction of the connecting socket when the engaging element inserts into the notch of the electrical connecting terminal
Data Source
AI summary
An electrical connection device includes a housing, a connecting socket, a conducting contact element, an elastic element, and an engaging element. The housing has a bottom portion, a top portion, and a side portion. The bottom portion has an opening configured for an electrical connecting terminal to pass through. The connecting socket is coupled to the housing. The connecting socket has a mating portion and a connecting portion connected to each other. The mating portion is in the housing and has a mating hole. The mating hole is interconnected to the opening. The conducting contact element is in the mating hole. The elastic element is between the mating portion and the side portion. The engaging element is coupled to the housing and configured to insert into a notch of the electrical connecting terminal.