Multi-Phase Electrical Connectors With Integral Fault Indication
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Solution Overview
Problem
Existing electrical connectors for AC multi-phase cables lack integral fault detection and indication capabilities, particularly for temperature and phase-ground swap faults, which can lead to equipment damage and safety hazards.
Innovation Solution
Incorporating a detector and indicator system within electrical connectors to monitor temperature and phase-ground faults, using thermal sensors and indicators such as thermistors and light-emitting diodes (LEDs) to signal fault conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fault detection and indication capabilities are integrated into electrical connectors, then safety and reliability are improved, but device complexity increases
Solution Approach 1:
The patent combines the fault detection function with the electrical connector by integrating temperature sensors and phase-ground swap detectors directly into the connector body. The detector circuit is merged with the connector structure, and the indicator (LED) is incorporated into the connector housing, creating a unified device that performs both connection and monitoring functions.
Solution Approach 2:
The electrical connector is designed to perform multiple functions: it provides electrical connection between phases and ground, monitors temperature at contact points, detects phase-ground swap faults, and provides visual indication of fault conditions. This multi-functional design eliminates the need for separate monitoring devices.
2Object-affected harmful factors
If temperature monitoring is implemented at phase contacts, then equipment damage from overheating is prevented, but device complexity and manufacturing cost increase
Solution Approach 1:
Temperature sensors (thermistors) are placed specifically at the phase contacts where overheating is most likely to occur. This localized monitoring approach focuses protection where it is most needed without requiring temperature sensing throughout the entire connector structure.
Solution Approach 2:
The temperature monitoring system uses the connector's own structure and materials to facilitate detection. The thermistors are integrated into the contact areas, and the detector circuit uses the existing electrical paths to monitor temperature, allowing the connector to monitor itself without external intervention.
3Reliability
If phase-ground swap detection is added, then safety hazards are reduced, but device complexity increases
Solution Approach 1:
The phase-ground swap detector continuously monitors the electrical connections to detect improper wiring or contact degradation before they cause dangerous conditions. The system performs preliminary detection of potential faults, allowing for early intervention before equipment damage or safety incidents occur.
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
Enhances safety and productivity by continuously monitoring and indicating electrical connector conditions, facilitating preventive maintenance and compliance with safety standards.
Implementation Method 1
The detector is configured to monitor a first temperature associated with the first phase contact, a second temperature associated with the second phase contact, and a third temperature associated with the third phase contact
Implementation Method 2
The indicator is operatively coupled to the detector and is configured to indicate the presence of the temperature fault
Data Source
AI summary
Electrical connectors with integral fault detection are provided. The connectors are adapted to be coupled to AC multi-phase electrical cables, and can include a plurality of phase contacts, a detector, and an indicator. The phase contacts include a first phase contact, a second phase contact, and a third phase contact to receive a first phase, a second phase, and a third phase, respectively, of the electrical cable. The detector is configured to monitor a first temperature associated with the first phase contact, a second temperature associated with the second phase contact, and a third temperature associated with the third phase contact to detect a temperature fault at any of the contacts. The indicator is operatively coupled to the detector and is configured to indicate presence of the temperature fault.