Modular High-Current Connector Assembly for Expandable Current Capacity
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Solution Overview
Problem
Existing high-current connectors lack modularity to adapt to different applications, limiting their versatility and current transmission capacity.
Innovation Solution
A modular high-current connector design comprising interconnected housing parts with screw connections, crimp technology for electrical connections, and a pin contact system that allows expansion by adding additional housing parts, enabling higher current transmission through parallel connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed-size high-current connector is used for a specific application, then the connector design is simple and manufacturing is easier, but the connector cannot be adapted to different applications or current requirements
Solution Approach 1:
The connector housing is divided into multiple modular sections that can be connected in series. Each section contains contact elements and can be independently manufactured, then assembled to create connectors with different current capacities (400A, 800A, 1200A) by varying the number of sections.
Solution Approach 2:
The modular sections are designed with standardized interfaces and universal components that can be used across different connector configurations. The same basic section design serves multiple current ratings when combined in different quantities, reducing the need for multiple unique designs.
2Power
If multiple housing sections are connected in series to increase current transmission capacity, then higher currents (up to 1200A) can be transmitted, but the connector length and overall size increase
Solution Approach 1:
Instead of extending connector length linearly to increase current capacity, the design uses parallel arrangement of contact elements within modular sections. Multiple housing sections are connected in parallel electrically while being arranged compactly, allowing high current transmission without proportional length increase.
3Adaptability or versatility
If modular housing sections are used to enable expansion and adaptation, then the connector can be customized for different applications, but the device complexity and number of components increases
Solution Approach 1:
The modular housing sections are designed to nest or connect compactly to each other, with integrated mounting features and alignment mechanisms. This nesting approach allows multiple sections to be assembled in a space-efficient manner, reducing the overall complexity despite the modular design.
4Reliability
If crimp connection technology is used for electrical connections, then vibration resistance and connection durability are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The crimp connection geometry and positioning features are pre-designed and pre-positioned during housing section manufacturing. Alignment pins,定位 features, and pre-formed crimp zones are incorporated into the modular sections before final assembly, ensuring precise electrical connections without requiring high-precision field operations.
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 modular design allows for adaptable current transmission from 400A to 1200A by adding more lines, providing a durable and vibration-resistant solution suitable for various applications, particularly in the railway sector.
Implementation Method 1
A crimp connection offers high vibration protection. This type of connection technology is therefore particularly popular in the railway sector.
Implementation Method 2
The connection between the two housing parts can be realized via a screw connection.
Implementation Method 3
Higher currents can be transmitted via the pin contact via multiple lines connected in parallel. For example, the high-current connector can transmit 400A with one line, 800A with two lines, and 1200A with three lines.
Data Source
Figure 1~2
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Figure 6
AI summary
The invention relates to a modular high-current connector (1) having a first housing part (7) and a second housing part (8) connected thereto, the second housing part (8) having an open housing wall (10). The open housing wall (10) can be added to by an unlimited number of additional housing parts.