Plug Connection Locking Clip for Load-Free Disconnection
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Solution Overview
Problem
Existing plug connection systems fail to reliably prevent disconnection under load, leading to arcing, sparking, and potential damage, and often require complex electronics or limited compatibility with other connector systems.
Innovation Solution
A device comprising a locking lever, sensor system, and plug detector that ensures a load-free disconnection by controlling an electrical disconnecting device, preventing disconnection and connection under load through a logical evaluation of sensor signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple plug connection system is used, then device complexity is reduced, but reliability of preventing disconnection under load deteriorates
Solution Approach 1:
The locking lever is designed to automatically engage and lock the plug connection in the locked position before any disconnection can occur. This preliminary mechanical locking action prevents disconnection under load without requiring complex electronic detection systems, thereby maintaining simplicity while improving reliability.
Solution Approach 2:
The sensor system acts as an intermediary between the mechanical locking state and the electrical disconnecting device. The sensor detects the locking lever position and triggers the electrical disconnecting device to open contacts before the mechanical disconnection occurs, providing a reliable intermediate control step that prevents load disconnection without adding significant system complexity.
2Reliability
If an electronic switch and counter system is used, then reliability of safe shutdown is improved, but device complexity and cost increase
Solution Approach 1:
The invention extracts the essential safety function from complex electronic control systems and implements it through a simple mechanical locking lever combined with a basic sensor. The locking lever mechanically ensures the connection remains closed during operation, and the sensor only needs to detect this mechanical state to control the electrical disconnecting device, eliminating the need for complex electronic switches and counters.
Solution Approach 2:
The locking lever system is self-regulating through its mechanical design. The lever automatically engages the locked position when the plug is inserted and remains locked during operation. The sensor system passively detects this mechanical state and automatically triggers the electrical disconnecting device when unlocking is detected, providing self-service safety control without complex electronic intervention.
3Extent of automation
If a control voltage on a specific contact is used, then shutdown control is achieved, but adaptability with other connector systems deteriorates
Solution Approach 1:
The sensor system serves as an intermediary that decouples the shutdown control function from specific electrical contacts. Instead of using a control voltage on a specific contact, the sensor detects the mechanical locking state and triggers the electrical disconnecting device accordingly. This intermediary approach maintains automation while being independent of specific contact assignments, thereby improving adaptability.
Solution Approach 2:
The invention replaces electrical control (control voltage on specific contact) with mechanical detection (sensor detecting locking lever position). The mechanical locking lever state directly controls the electrical disconnecting device through the sensor, eliminating the need for dedicated control contacts and enabling compatibility with various connector systems that may have different contact configurations.
Data Source
Figure 1~2b
AI summary
The invention relates to a device for the load-free disconnection of a plug-in connection, which has an electrical disconnecting device (5) and a locking clip (3). The locking clip (3) can be pivoted both into a position locking the plug-in connection and into a position unlocking the plug-in connection. The device also has a sensor system (4), which interacts with the locking clip (3) in its locking position to detect the locked state, in order to control the electrical disconnecting device (5).