Overvoltage Protection Device Asymmetric Locking Mechanism
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Solution Overview
Problem
Modular overvoltage protection devices face issues with incorrect plug insertion, contact disruption due to electromechanical forces, and vibration-induced disconnection, while also requiring high force for removal and occupying space with status displays, which contradicts the demand for compact designs.
Innovation Solution
An overvoltage protection device ensemble with a holder and plug design featuring a form-fitting locking mechanism, spring-loaded unlocking devices, and a status display coupled to the unlocking mechanism, allowing secure locking and automatic ejection of defective plugs, along with an ejection mechanism and external force unlocking for manual removal, while minimizing material usage and space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If modular design with plug-in elements is used, then quick replacement is achieved, but incorrect insertion and contact disruption occur
Solution Approach 1:
The plug-in element features an asymmetric design where the contact surfaces and locking mechanism are positioned to allow insertion in only one correct orientation. The holder includes guide elements and the plug includes corresponding engagement surfaces that geometrically constrain correct alignment, preventing incorrect insertion while maintaining quick replacement capability.
Solution Approach 2:
The locking mechanism is designed to automatically engage as soon as the plug-in element is inserted into the holder, without requiring additional manual steps. The spring-loaded locking element pre-positioned in the holder automatically latches with the corresponding feature on the plug, ensuring immediate secure connection upon insertion.
2Reliability
If retaining elements are added to prevent loosening, then connection stability is improved, but removal requires great force or tools
Solution Approach 1:
The locking mechanism uses a spring-loaded element that dynamically adjusts its locking force. During normal operation, the spring maintains strong engagement to prevent loosening from vibrations and electromechanical forces. During removal, an ejection mechanism applies dynamic force to overcome the spring lock, allowing tool-free extraction without requiring excessive manual force.
Solution Approach 2:
An ejection mechanism serves as an intermediary between the user and the locked plug-in element. This mechanism, activated by a simple button or lever, applies controlled force to the locking element to release it, facilitating easy removal without tools while maintaining secure locking during operation.
3Loss of information
If status display is added, then device status monitoring is improved, but device size increases
Solution Approach 1:
The status display function is merged with the existing locking mechanism structure. The locking element itself serves as the status indicator - its position (locked or unlocked) visually indicates the operational status of the plug-in element. Additionally, the status LED is integrated into the holder housing rather than requiring separate display space, combining multiple functions within the existing form factor.
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
Ensures secure and automatic locking and ejection of overvoltage protection devices, reduces material and space requirements, and provides a compact solution with enhanced reliability and ease of maintenance.
Implementation Method 1
at least one spring-loaded unlocking device E1
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a surge protection device assembly (1) comprising a holder (H) for receiving a surge protection device plug (SPD), wherein the holder (H) is designed for a substantially positive-locking receipt of the surge protection device plug (SPD), wherein the holder (H) has a locking device (V) which holds an inserted surge protection device plug (SPD) in the holder (H) so that it cannot be removed from the holder, wherein the surge protection device plug (SPD) comprises a surge protection device (SPD) and a first release device (E1), wherein the first release device (E1) can act on the locking device (V) in such a way that the surge protection device plug (SPD) can be removed from the holder in a first warning state of the surge protection device (SPD).