Plug Connector Sleeve Structure to Prevent Partial Discharge
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Solution Overview
Problem
Existing plug connectors used in high-current and high-voltage applications, such as in the railway industry, are prone to partial discharges due to their complex geometry, particularly in the coupling region, which compromises their operational reliability.
Innovation Solution
The plug connector design incorporates a partial-discharge sleeve that encases the coupling part of the contact element, providing a homogeneous surface and uniform potential, thereby preventing partial discharges and ensuring a reliable electrical connection through a peripheral contact strip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a two-part contact element with orthogonal orientation is used to transmit high currents, then the current transmission capability is improved, but partial discharges occur locally in the coupling region
Solution Approach 1:
A partial-discharge sleeve is introduced as an intermediary component between the coupling part and the insulating body. This sleeve serves as a mediator that shapes the electrical field and prevents partial discharges by providing a homogeneous surface transition, thereby protecting the two-part contact element while maintaining its high current transmission capability
Solution Approach 2:
The partial-discharge sleeve acts as a protective shell that encases the coupling part. This shell structure provides a smooth, homogeneous surface that eliminates air gaps and prevents the initiation of partial discharges, while allowing the underlying two-part contact element structure to maintain its functional geometry for high current transmission
2Adaptability or versatility
If the coupling part has a complex geometry for orthogonal insertion, then the plug connector functionality is improved, but the surface becomes non-homogeneous leading to partial discharges
Solution Approach 1:
The partial-discharge sleeve functions as a protective shell that covers the complex geometry of the coupling part. It provides a homogeneous outer surface that eliminates air gaps and non-uniform electric field distributions, thereby preventing partial discharges while allowing the complex internal geometry to maintain its plug connector functionality
Solution Approach 2:
The partial-discharge sleeve serves as an intermediary layer between the complex coupling part geometry and the insulating body. It mediates the electrical field distribution by providing a smooth, homogeneous surface transition, preventing the harmful effects of geometric complexity from causing partial discharges
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
The design effectively prevents partial discharges, allowing for higher operating voltages and improved reliability by ensuring a homogeneous surface and uniform potential within the plug connector.
Implementation Method 1
a so-called partial discharge may occur locally, particularly in the coupling region
Implementation Method 2
The partial-discharge sleeve may comprise or consist of an electrically conducting material, in particular of metal
Data Source
AI summary
A plug connector is provided, exhibiting a plug-connector housing, an insulating body and at least one two-part contact element, consisting of a coupling part and a contact part, the plug connector further exhibiting a partial-discharge sleeve, and the coupling part of the contact element being arranged at least partially within the partial-discharge sleeve.