Power Connector Integrated Sensor Monitoring
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Solution Overview
Problem
Existing electrical power connectors lack the capability for continuous, accurate monitoring of power consumption and environmental conditions, such as temperature, which hinders efficient energy cost allocation and predictive maintenance.
Innovation Solution
Incorporating a transformer winding and sensor slot within the contact core of the power connector to sense current and temperature, allowing for real-time monitoring and wireless transmission of characteristics like current, voltage, and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional electrical power connectors are used without integrated sensors, then the device complexity is low, but the measurement precision of power consumption and environmental conditions is insufficient
Solution Approach 1:
The patent combines the power connector with integrated sensors (temperature, current, voltage) and a processor into a single unified device. The sensor slot is incorporated directly into the contact core, and the processor is embedded within the connector housing, merging previously separate components into one integrated system that provides accurate power monitoring while maintaining a compact form factor.
Solution Approach 2:
The power connector is designed to perform multiple functions simultaneously: it provides electrical power transmission through contacts, monitors temperature via integrated sensors, measures current through transformer windings, detects voltage, and transmits data wirelessly. This multi-functional design enables the connector to serve both as a power delivery mechanism and a comprehensive monitoring station.
2Productivity
If manual temperature scanning is used instead of continuous monitoring, then the device complexity is low, but the productivity of energy cost allocation and maintenance is reduced
Solution Approach 1:
The patent implements continuous monitoring of temperature, current, and voltage parameters through integrated sensors that operate constantly rather than through periodic manual scanning. The processor continuously processes sensor data, and the wireless transmitter continuously communicates with remote devices, ensuring uninterrupted monitoring of power consumption and environmental conditions for real-time energy cost allocation.
Solution Approach 2:
The monitoring system operates autonomously without requiring manual intervention. Sensors automatically detect environmental parameters, the processor independently analyzes the data against predetermined thresholds, and the wireless transmitter automatically sends alerts to remote devices when anomalies are detected, enabling the system to serve itself without human operation.
3Reliability
If integrated sensors and processing units are added to the power connector, then the reliability of power consumption monitoring is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The connector is divided into distinct functional modules: the contact core with integrated sensor slot, the processor unit, the wireless transmitter module, and the housing. This segmentation allows each component to be manufactured and tested separately using standardized procedures, then assembled into the complete monitoring system, reducing the overall manufacturing precision requirements while maintaining reliable sensor integration.
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
Enables continuous, accurate monitoring of power consumption and environmental conditions, facilitating efficient energy cost allocation and predictive maintenance by providing real-time data for operators.
Implementation Method 1
The contact core includes a transformer winding configured to sense a current
Data Source
AI summary
An electronic power connector including a contact configured to electrically connect a power supply to a load. The electronic power connector further including a contact core configured to receive the contact, the contact core including a transformer winding wrapped around the contact core, the transformer winding configured to sense a current.