Power Connector Spacer for High Voltage Pin Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Testing high voltage power circuits with pinned connectors poses a hazard due to the risk of short circuits and arc flashes when attempting to measure voltage, as traditional methods require probing pins directly, which can lead to unintended contact and electrical discharge.
Innovation Solution
A power connector spacer system that uses a non-conducting spacer with passageways to isolate and safely measure the voltage of individual power pins, providing a tactile confirmation of connection and preventing inadvertent contact, while also shunting charge potential to ground to prevent hazardous discharges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional direct probing method is used to measure voltage of power pins, then measurement simplicity is maintained, but safety risk increases due to risk of short circuits and arc flashes
Solution Approach 1:
A non-conducting spacer with isolated passageways is introduced as an intermediary device between the meter probe and the power pins. The spacer provides individual isolated pathways for each pin, allowing voltage measurement while preventing contact between adjacent pins. This intermediary structure eliminates the short circuit hazard while maintaining the ability to measure each pin's voltage safely.
2Reliability
If non-conducting spacer with passageways is used to isolate power pins, then safety against short circuits is improved, but measurement precision may be affected by isolation requirements
Solution Approach 1:
The spacer is segmented into multiple isolated passageways, each dedicated to a specific power pin. This segmentation physically separates the measurement paths for adjacent pins, preventing electrical interference and short circuits while allowing each pin to be measured independently with full precision. The non-conducting material between passageways ensures complete electrical isolation.
3Ease of operation
If direct contact method is used for voltage measurement, then tactile confirmation is obtained, but risk of inadvertent contact and electrical discharge increases
Solution Approach 1:
The non-conducting spacer acts as a mediator that allows the meter probe to make tactile contact with each power pin through its own isolated passageway. The probe can be inserted and confirmed to contact the pin, but the non-conducting walls of the passageway prevent any electrical discharge or short circuit even if the probe accidentally contacts adjacent pins or other conductive surfaces.
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 safe and accurate measurement of high voltage power circuits by isolating power pins within the spacer, reducing the risk of short circuits and arc flashes, and ensuring reliable tactile confirmation of electrical contact, thereby enhancing worker safety during maintenance and testing.
Implementation Method 1
A non-conducting power connector spacer may be inserted into the receptacle of the male power connector in place of the corresponding female power connector by aligning a plurality of passageways formed in the power connector spacer with respective power pins extending from the base of the male power connector
Implementation Method 2
providing a tactile confirmation of connection and preventing inadvertent contact, while also shunting charge potential to ground to prevent hazardous discharges
Data Source
AI summary
A power connector spacer system includes a non-conducting body for insertion into a receptacle of a male power connector in place of a corresponding female power connector. The body may include a latch dimensioned and configured to detachable couple with an interior surface of the receptacle of the male power connector. The body may also include a flange dimensioned to abut a rim of the receptacle, and non-conducting passageways extending through the body from the proximate end to a distal end. Each of the passageways may be dimensioned to receive and isolate one of a plurality of power pins included in the receptacle of the male power connector, and a respective end of each of the power pins may be disposed in respective passageways away from the distal end of the body for isolated detection of high voltage electric power by contact with a meter probe in respective the passageways.