Offset High-Power Plug Layout With Conductive Rail Connection
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Solution Overview
Problem
Existing high-performance connector systems for rail-bound vehicles face challenges in providing a space-saving, safe, and cost-effective solution for transmitting and distributing high electrical currents, particularly in sub-area applications where maintenance and space constraints are significant.
Innovation Solution
A high-performance connector system featuring a cable connection housing that absorbs multiple insulating bodies with profiling, which securely hold high-performance contacts arranged on one level with offset longitudinal axes. The system uses an electrically conductive rail to connect the contacts, reducing spatial requirements and incorporating recesses and grooves for enhanced stability and maintenance access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional connector systems are used for high current transmission, then electrical connection is achieved, but space requirements increase and maintenance becomes difficult
Solution Approach 1:
The connector system is divided into separate modular components: a first connector with a first contact element and a second connector with a second contact element. These modules can be independently accessed, installed, and maintained. The cable connection housing also separates insulating bodies for different contacts, allowing targeted maintenance of individual high-performance contacts without replacing the entire system.
Solution Approach 2:
Multiple high-performance contacts are arranged in a three-dimensional configuration within the cable connection housing, with insulating bodies positioned at different spatial locations. This vertical and lateral arrangement optimizes space utilization while maintaining adequate clearance distances for maintenance access and electrical insulation.
2Power
If high-performance contacts are used for high currents, then current transmission capability is improved, but electrical erosion increases and wear accelerates
Solution Approach 1:
The contact elements are designed with specific geometric parameters optimized for high current carrying capacity. The high-performance contacts feature enlarged cross-sectional areas and optimized contact surface geometries that reduce current density and minimize electrical erosion. The insulating bodies are dimensioned to provide adequate creepage and clearance distances that prevent flashover and enhance reliability under high voltage and current conditions.
3Area of stationary object
If multiple high-performance contacts are accommodated in a single housing, then space efficiency is improved, but device complexity increases
Solution Approach 1:
The cable connection housing serves multiple functions simultaneously: it provides mechanical protection for all contact elements, establishes electrical insulation between different contacts through the insulating bodies, defines the spatial arrangement of multiple connectors, and provides mounting structures for secure connection. This multi-functionality reduces the need for separate protective structures for each contact.
Solution Approach 2:
Multiple insulating bodies are integrated into a single cable connection housing structure, combining what could have been separate protective enclosures into one unified component. The insulating bodies are positioned to simultaneously provide insulation for multiple contacts while maintaining adequate clearance distances, thereby simplifying the overall structure compared to using separate housings for each contact.
Data Source
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AI summary
The invention relates to a high-power plug connection system consisting of a cable connection housing for connecting at least two electric high-power plug connectors in order to transmit and/or distribute high current strengths and at least two insulating bodies for receiving a respective high-power contact and at least one electrically conductive rail, wherein the longitudinal axes of the high-power contacts are generally arranged on one plane in an offset manner from each other, and the high-power contacts are connected together in an electrically conductive manner by means of an electrically conductive rail, said at least two high-power contacts being provided with a recess into which the electrically conductive rail is at least partly inserted.