Plug-In Connector With Temperature Sensing for Inverter Copper Bars
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Solution Overview
Problem
The existing connection methods between inverter modules and reactors using copper bars and screws result in low disassembly efficiency, increased maintenance costs, and overheating risks, affecting the operation reliability of power conversion devices.
Innovation Solution
A plug-in device with a housing, connector, and temperature acquisition device that allows quick disassembly and real-time temperature monitoring, converting temperature data into digital signals to control the radiator for heat dissipation, thereby reducing overheating and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper bars are connected by screw fastening to reduce contact resistance, then the contact resistance is small and overheating is avoided, but the disassembly efficiency is low and maintenance downtime is increased
Solution Approach 1:
The connector is divided into a plug-in unit with clamping parts and a fixed connection part, allowing the copper bar connection to be segmented into removable plug-in sections and fixed sections. This enables quick disassembly of the plug-in unit while maintaining the fixed connection part, significantly reducing maintenance downtime while preserving connection reliability through the fixed connection.
Solution Approach 2:
The connector transitions from a static screw-fastened design to a dynamic plug-in design where the clamping parts can be quickly inserted and removed. This dynamic structure allows the connection to be easily reconfigured for maintenance while maintaining electrical contact through the clamping mechanism, balancing connection reliability with maintenance efficiency.
2Productivity
If plug-in unit is used to improve disassembly efficiency, then maintenance efficiency is improved and downtime is reduced, but the contact area between conductors is reduced causing increased resistance and overheating risk
Solution Approach 1:
The connector design applies local quality by providing different connection characteristics in different areas: the clamping parts provide localized high-pressure contact points that concentrate force on small areas to maintain low contact resistance, while the fixed connection part provides stable structural support. This localized optimization maintains operation reliability despite the plug-in design.
Solution Approach 2:
The clamping parts are pre-configured with spring mechanisms that automatically apply sufficient clamping force when the plug-in unit is inserted, ensuring low contact resistance is achieved automatically during the plugging process. This preliminary action of pre-loading the springs ensures reliable electrical connection without requiring additional adjustment steps.
3Reliability
If temperature monitoring is added to prevent overheating, then operation reliability is improved, but the device complexity is increased
Solution Approach 1:
The temperature acquisition device automatically monitors the temperature at the overlapping position and provides feedback to the control unit, which then autonomously adjusts the clamping force or triggers alarms without requiring external intervention. This self-service capability improves operation reliability through continuous monitoring while minimizing the added complexity by using automated control rather than manual inspection systems.
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 plug-in device enables efficient maintenance, reduces downtime and costs, and ensures reliable operation by preventing overheating and extending the lifespan of power conversion devices.
Implementation Method 1
The temperature acquisition device is arranged close to the connector, and is configured to acquire a temperature at an overlapping position of the power conversion device
Implementation Method 2
The connector includes a spring component. The spring component is configured to clamp the power conversion device
Implementation Method 3
The fixed connection part is configured to connect to a first copper bar
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A plug-in device and a power conversion apparatus are provided. The plug-in device includes a housing, a connector and a temperature acquisition device. The housing is defined with a holding cavity. The connector includes a clamping part and a fixed connection part. The clamping part is arranged in the holding cavity. The fixed connection part partially extends out of the housing. The clamping part is configured to clamp a power conversion device. The fixed connection part is connected to a reactor. The temperature acquisition device is arranged close to the connector, and is configured to acquire a temperature at an overlapping point of the power conversion device and the clamping part. In the present disclosure, quick plug-in and plug-out of the copper bar of the power conversion device is realized by using the clamping part of the connector, so that the power conversion device can be quickly disassembled, reducing maintenance costs and downtime, thereby improving the efficiency of maintaining the power conversion device. With the temperature acquisition device, the temperature at the overlapping position of the clamping part of the connector and the copper bar of the inverter is monitored in real time, so that intervention is performed before a failure of the plug-in device caused by overheating at the overlapping position.