Modular Connector Assembly for Fast EV Battery Pack Replacement
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Solution Overview
Problem
Existing electric vehicle battery pack connector assemblies are complex, bulky, and costly due to the integration of signal and power connectors, requiring replacement of the entire assembly when a connector fails.
Innovation Solution
A modular connector assembly with separate high-voltage and low-voltage connectors, each with detachable installation, allowing for independent replacement and simplification of the structure, reducing weight and volume, and enabling quick installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If multiple different signal connectors are provided to achieve fast electrical connection with battery packs, then electrical connection speed is improved, but device complexity and volume increase
Solution Approach 1:
The patent combines multiple different signal connectors and power connectors into a single integrated connector assembly. The insulator houses multiple terminal types (signal terminals, power terminals, grounding terminals) within one unified structure, eliminating the need for separate connector components and reducing overall system complexity while maintaining fast connection capability.
Solution Approach 2:
The integrated connector assembly serves multiple functions simultaneously - it provides signal transmission, power transmission, and grounding functions through different terminal types within a single connector structure. This multi-functional design reduces the number of separate connectors needed while achieving comprehensive electrical connection capabilities.
2Device complexity
If signal connector and power connector are integrated into the same insulator, then connection assembly is simplified, but repairability deteriorates as entire assembly must be replaced when a connector fails
Solution Approach 1:
The connector assembly is segmented into modular components - the insulator housing and the terminal assemblies. Each terminal type (signal, power, grounding) can be independently accessed and replaced. The terminal assemblies are detachably connected to the insulator, allowing individual terminal replacement without replacing the entire connector assembly, thus improving repairability while maintaining structural integration.
3Reliability
If entire connection assembly is replaced when a connector encounters a problem, then reliability is maintained, but cost increases
Solution Approach 1:
The modular terminal assembly design allows for selective replacement of only the faulty terminal component while retaining functional terminals. When a terminal encounters a problem, only that specific terminal assembly needs to be replaced rather than the entire connector assembly, reducing material waste and replacement costs while maintaining reliable electrical connection through the replacement of critical components only.
Data Source
AI summary
A connector assembly includes an installation seat having a pair of first installation holes and a second installation hole, a pair of first connectors respectively detachably inserted into the first installation holes, and a second connector detachably inserted into the second installation hole. Each of the first connectors has a power terminal. The second connector has a signal terminal and a grounding terminal.