Electrical Plug Blocking Mechanism for Complete HV Connector Mating
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Solution Overview
Problem
Existing electrical plug devices for high-voltage connections, such as those in electric vehicles, lack a reliable mechanism to prevent incomplete or improper plugging and ensure a sealed connection, which can lead to safety and reliability issues.
Innovation Solution
An electrical plug device with a connector housing, a connection aid, a position assurance element, and a blocking mechanism that allows the connection aid to move from a plugging position to a holding position, while the blocking mechanism is released when the connector and mating housings are fully plugged, ensuring a secure and sealed connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the position assurance element is always displaceable, then operation is simple, but incomplete plugging cannot be prevented
Solution Approach 1:
The position assurance element transitions from a static blocked state to a dynamic displaceable state based on the plugging condition. The blocking mechanism dynamically controls the element's mobility: blocked during improper plugging attempts, and released only when the connector housing and mating housing are properly plugged together, as detected by the release element.
2Reliability
If a blocking mechanism is added to prevent incomplete plugging, then plugging completeness is ensured, but device complexity increases
Solution Approach 1:
The blocking mechanism is merged with the existing position assurance element and connection aid structure. The release element is integrated into the housing assembly, and the blocking mechanism shares structural elements with the position assurance element, reducing the need for separate independent components and minimizing overall complexity.
Data Source
AI summary
An electrical plug device includes a connector housing pluggable with a mating housing, a connection aid engageable with the mating housing, a position assurance element held at the connector housing and displaceable from an open position to a securing position, and a blocking mechanism. The connection aid is movable from a plugging position to a holding position. The connector housing in the plugging position is connectable to the mating housing. The mating housing in the holding position is held at the connector housing. The connection aid in the open position is movable from the plugging position to the holding position and in the securing position is fixated in the holding position. The blocking mechanism blocks the position assurance element in the open position and has a release element with which the blocking mechanism is released in a state of the connector housing and the mating housing being plugged together.