Marine Cable Connection Assembly with Arcing Prevention
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Solution Overview
Problem
Conventional outboard motors face challenges with heavy and unwieldy cables due to high current power requirements for electric motors, and there is a need for secure data connections in electric boat power installations.
Innovation Solution
The development of cable connection assemblies that combine power, signal, and interlock lines in a single cable, featuring a latching mechanism and insulating bodies to reduce arcing and misalignment, with a design that includes a flange for electromagnetic interference shielding and a secure, water-resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high current levels are used to provide power for electric outboard motors, then power delivery capability is improved, but cable weight and handling difficulty increase
Solution Approach 1:
The patent combines multiple functions (power transmission, data communication, and interlock signaling) into a single integrated cable assembly. This consolidation reduces the total cable weight compared to using separate cables for each function, while still delivering the required high current levels for power.
Solution Approach 2:
The cable assembly is designed to perform multiple functions simultaneously: transmitting high current power, carrying data signals, and providing interlock status. This multi-functionality allows a single cable to replace what would traditionally require multiple separate cables, reducing overall weight and simplifying the electrical system.
2Adaptability or versatility
If separate cables are used for power and data connections, then functional separation is improved, but connection security and system reliability deteriorate
Solution Approach 1:
The patent integrates power conductors, data conductors, and interlock conductors into a single cable assembly with a unified connector. This ensures that all connections are made simultaneously in a single mating action, eliminating the risk of incomplete or improper connections that could occur with separate cables, thereby improving reliability.
Solution Approach 2:
The connector design includes preliminary alignment features and a sequencing mechanism that ensures connections are made in a predetermined order. This preliminary action ensures that all electrical and data connections are properly established before the connection is considered complete, enhancing connection security.
3Ease of manufacture
If simple connector design is used, then ease of manufacture is improved, but protection against electrical arcing and misalignment deteriorates
Solution Approach 1:
The connector incorporates insulating bodies at specific locations where electrical arcing could occur. These localized insulating features provide protection against arcing and misalignment only where needed, rather than requiring complete redesign of the entire connector. This approach maintains manufacturing simplicity while adding targeted protection.
Solution Approach 2:
Insulating bodies serve as intermediary elements between conductive components, preventing direct contact that could cause electrical arcing. These intermediaries are strategically placed to block harmful electrical discharge paths while maintaining the overall simplicity of the connector design.
4Object-affected harmful factors
If robust shielding and protection features are added, then protection against electromagnetic interference and water resistance is improved, but device complexity increases
Solution Approach 1:
The patent combines electromagnetic shielding and water resistance features into the existing connector structure without adding separate independent systems. The shielding is integrated as a layer within the connector housing, and water resistance is achieved through sealing features that are part of the basic connector design, thereby minimizing the increase in overall complexity.
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 simplifies connections, reduces the likelihood of electrical arcing, and provides a robust, water-resistant, and easy-to-handle cable assembly that can withstand repeated use, addressing the challenges of high current power transmission and secure data connections in marine propulsion systems.
Implementation Method 1
a design that includes a flange for electromagnetic interference shielding
Data Source
AI summary
Cable connection assemblies for marine propulsion, and associated systems and methods are disclosed. A representative connection assembly includes a multi-conductor cable having two high voltage power conductor lines, two low voltage power conductor lines, two interlock lines, and two signal lines. The assembly further includes a connector having a connector body carrying connection elements corresponding to each of the conductor lines, interlock lines, and signal lines. In further representative embodiments, one or more of the connection elements can be housed in corresponding insulating bodies. In still further representative embodiments, the assembly can be configured so that the high voltage lines are the first to mate, and the last to un-mate, which, together with the interlock loop, can reduce or eliminate the likelihood for high voltage arcing.