Vehicle Power Connector Interlock for Full-Engagement Current Blocking
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Solution Overview
Problem
Conventional power distribution components in motor vehicles face challenges such as space constraints, harsh operating conditions, and high failure rates due to incorrect installation and dislodgment, leading to significant repair and warranty costs.
Innovation Solution
A connector system with an interlock assembly and a spring member that ensures proper positioning and prevents electrical current from flowing until the connector is fully engaged, utilizing a female interlock assembly and male interlock assembly to control current flow and include a centering mechanism for the spring member within the terminal assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power distribution components are used without interlock systems, then the device complexity is reduced, but the reliability deteriorates due to incorrect installation and dislodgment
Solution Approach 1:
The interlock system performs preliminary actions by preventing electrical current flow until the connector is fully engaged. The interlock circuit keeps the electrical load disconnected during the connection process, and only enables current flow after proper engagement is confirmed, thereby preventing incorrect installation and dislodgment issues
Solution Approach 2:
The interlock assembly acts as an intermediary mechanism between the connector components and the electrical circuit. It includes an interlock circuit that mediates the electrical current flow, preventing it until the mechanical interlock confirms proper connection, thus resolving the contradiction between simplicity and reliability
2Reliability
If connectors are designed for secure engagement with interlock systems, then the reliability improves, but the ease of operation deteriorates due to more complex engagement procedures
Solution Approach 1:
The connector system incorporates self-service features where the interlock mechanism automatically prevents current flow during installation and only enables it after proper engagement. The spring member with centering means automatically positions components correctly, reducing the need for manual intervention and complex procedures while maintaining high reliability
3Manufacturing precision
If spring members are added with centering means, then the manufacturing precision improves, but the ease of manufacture deteriorates
Solution Approach 1:
The spring member incorporates centering means that enable self-alignment during assembly. The spring member with centering means automatically positions itself and other components in the correct alignment, eliminating the need for complex external alignment tools or procedures, thus improving manufacturing precision without significantly complicating the assembly process
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 connector system effectively reduces failure rates and repair costs by ensuring proper engagement and alignment of components, preventing electrical current flow until full connection is established, thus enhancing reliability and longevity in harsh vehicle environments.
Implementation Method 1
an internal spring member having a spring arm
Data Source
AI summary
The connector system is configured for use in a power distribution system of a motor vehicle, and wherein the connector system includes a female housing, female terminal assembly, and a female interlock (FIL) assembly. The female housing having an arrangement of side walls that define a receptacle that is configured to receive the female terminal assembly. The female interlock (FIL) assembly positioned within the female terminal assembly that resides within the receptacle of the female housing to define a fully assembled female state SFAF, whereby the FIL assembly is configured to be coupled to an interlock circuit that prevents electrical current from flowing through the female terminal assembly prior to connection of the female terminal assembly to a male terminal assembly.