Movable High-Voltage Plug Connection for Tolerance Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current high-voltage component connections, particularly in high-voltage batteries, face complexity due to tilting issues caused by component tolerances, leading to challenging assembly and potential safety risks.
Innovation Solution
A plug connection design with movable mounting of high-voltage terminals within a housing, allowing for compensation of component tolerances and improved coupling, featuring flexible conductor connections and insulating layers for enhanced safety and environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid mounting of high-voltage terminals is used, then structural stability is improved, but tilting occurs due to component tolerances leading to complex assembly
Solution Approach 1:
The patent applies the dynamics principle by making the high-voltage terminal mounting movable rather than rigid. The terminal is mounted on a movable support structure that allows adjustment in multiple directions (x, y, z axes and rotation), enabling the system to adapt to component tolerances and prevent tilting during assembly while maintaining structural stability through controlled movement constraints.
2Device complexity
If movable mounting of high-voltage terminals is implemented, then assembly complexity is reduced, but electrical insulation and shock protection become more challenging
Solution Approach 1:
The patent applies segmentation by dividing the housing into multiple independent components: a first housing component for the first high-voltage terminal, a second housing component for the second high-voltage terminal, and a third housing component. Each housing component provides independent electrical insulation and shock protection for its respective terminal, allowing movable mounting while maintaining insulation reliability through modular design.
3Reliability
If separate housing components are used for each high-voltage terminal, then electrical insulation is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing the housing components to serve multiple functions simultaneously. Each housing component not only provides electrical insulation but also mechanically mounts the high-voltage terminal, provides shock protection, and enables movable mounting. The third housing component serves as both a protective enclosure and a mounting structure for the movable support, reducing overall device complexity despite using separate components.
Data Source
AI summary
A plug connection for coupling a first and a second electrical connection of a first high-voltage component to a first and a second electric connection of a second high-voltage component, wherein the plug connection is provided with a housing in which is arranged as a first pair of high-volt terminals for coupling to the first and the second electric connection of the high-voltage component as well as a second pair of high-voltage terminals for coupling to the first and to the second electric connection of the second high-voltage component, wherein at least the first and the second high-voltage terminal are mounted so that they are movable relative to the second pair of connections of the plug connection in the housing.