Manual Service Disconnect Lever with Intermediate Blocking Position
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Solution Overview
Problem
Existing Manual Service Disconnect (MSD) systems for high voltage modules, such as those in hybrid or electric vehicle battery packs, are impractical for operators wearing thick safety gloves and often fail to provide sufficient time for the high voltage supply to power down before unplugging, leading to safety risks from electric arcs and component damage.
Innovation Solution
A single-lever MSD design with an outer housing configured to block the lever in an intermediate position, creating a temporization of at least 1 second, allowing the system's electronics time to power down the high voltage supply before unplugging, and allowing manipulation with thick safety gloves, including fireman gloves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-stage lever mechanism is used to ensure safe power down before unplugging, then the high voltage supply can be powered down safely, but the device becomes difficult to operate with thick safety gloves in confined spaces
Solution Approach 1:
The unplugging operation is segmented into two distinct phases: first actuating the lever to open the HVIL and trigger power down, then after a forced delay, actuating the latch to release the lever for complete disconnection. This segmentation ensures safety while maintaining operability with thick gloves through clear sequential steps
Solution Approach 2:
The intermediate position of the lever acts as a mediator between the locked and unlocked states. When the lever is actuated, it becomes trapped in an intermediate position that physically prevents immediate complete disconnection, forcing a safety delay while still allowing the operator to proceed with the unplugging sequence
2Productivity
If the lever is released immediately after opening the HVIL, then the unplugging sequence is faster, but electric arcs can occur damaging electronics and the operator
Solution Approach 1:
The system performs preliminary action by automatically powering down the high voltage supply and discharging capacitors before the operator completes the unplugging sequence. The lever mechanism is designed to trigger this preliminary power down action as soon as it is actuated, ensuring the harmful electric arcs are eliminated before the final disconnection occurs
Solution Approach 2:
The intermediate position of the lever serves as a temporal mediator, creating a forced delay period between opening the HVIL and completing the disconnection. During this intermediate state, the high voltage supply is already powered down but the physical connection remains, preventing arcs while maintaining circuit integrity
3Ease of operation
If a single lever design is used for ease of operation with thick gloves, then manipulation is easier, but sufficient temporization for power down may not be achieved
Solution Approach 1:
The intermediate position of the lever acts as a built-in temporal mediator that automatically enforces the required power down time. The mechanical design ensures the lever cannot move from the intermediate position to the unlocked position until the operator deliberately actuates the latch, creating a forced pause that matches the electronic power down duration
Solution Approach 2:
The system serves itself by using the operator's own action of actuating the latch as the trigger to complete the unplugging sequence. The intermediate position automatically provides the necessary time delay, and the system waits for the operator to voluntarily proceed, eliminating the need for external timing mechanisms or additional delays
Data Source
Figure 1~2A
Figure 2B~3
Figure 4
AI summary
The invention relates to a plug (1) for mating a receptacle (2) of a Manual Service Disconnect, MSD, the plug (1) comprising an outer housing (3) and a lever (4) arranged on the outer housing (3) and configured for pivotal movement relative to the outer housing (3) from a locked position (4-L) to an unlocked position (4-U). According to the invention, the outer housing (3) is configured for blocking or releasing the lever (4) in or from an intermediate position (4-I) between the locked position (4-L) and the unlocked position (4-U). The invention further relates to a corresponding receptacle (2) of a Manual Service Disconnect, a Manual Service Disconnect, and a method for unmating a Manual Service Disconnect of a high voltage module.