Plug Connector Fuse Assembly for Simplified EV Charging HVIL
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Solution Overview
Problem
Implementing two individual contact pairs for High-Voltage Interlock Loop (HVIL) functionality in charging sockets for electric vehicles is complex, space-consuming, and expensive, particularly when aiming for a combined AC and DC charging system that requires series connection of HVIL circuits.
Innovation Solution
A plug connector design featuring a single fuse circuit with a manually actuable fuse device that blocks the connection in a first state to deactivate electrical energy transmission, eliminating the need for multiple contact pairs and ensuring safety through a defined assembly and disassembly sequence, while allowing transmission of both direct and alternating current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two individual contact pairs for HVIL functionality are implemented in charging sockets, then safety function is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines two separate HVIL contact pairs into a single integrated fuse device with a common housing. The fuse device contains both HVIL contact pairs within one unit, reducing the total number of separate components while maintaining the required safety functionality. This merging approach simplifies the overall connector design and reduces assembly complexity.
Solution Approach 2:
The fuse device serves multiple functions simultaneously: it provides both HVIL contact pairs for safety monitoring, acts as a fuse for overcurrent protection, and provides a unified blocking mechanism. This multi-functional design eliminates the need for separate dedicated HVIL contact pairs, reducing device complexity while maintaining reliability.
2Reliability
If two individual contact pairs for HVIL functionality are implemented in charging sockets, then safety function is improved, but manufacturing cost increases
Solution Approach 1:
By merging two separate HVIL contact pairs into a single fuse device housing, the patent reduces the number of manufacturing steps, assembly operations, and quality control checkpoints. This consolidation lowers manufacturing costs while maintaining the required safety functionality through the integrated design.
3Device complexity
If a single fuse circuit with manually actuable fuse device is used, then device complexity is reduced, but safety deactivation capability must be maintained
Solution Approach 1:
The manually actuable fuse device provides multiple safety functions through a single mechanism: it can block both HVIL contact pairs simultaneously, interrupt the fuse circuit, and provide a unified deactivation point. This multi-functional approach maintains comprehensive safety deactivation capability while reducing the number of separate fuse circuits and associated components.
Data Source
AI summary
A plug connector for establishing a plug connection together with a mating plug connector includes: at least one first connecting portion for connecting to a first connecting device to transmit electrical energy and/or electrical signals; a fuse circuit for deactivating a transmission of electrical energy; and at least one fuse device actuable and operatively connected at least to the at least one first connecting portion and to the fuse circuit, the at least one fuse device, in a first state, blocking the at least one first connecting portion for establishing a connection with the first connecting device and at least interrupting the fuse circuit to deactivate the transmission of electrical energy.