Power Feeding Control Apparatus Lead Plate Assembly
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Solution Overview
Problem
The assembly of conventional power feeding control apparatuses is challenging due to bent lead lines passing through zero current transformers, making it difficult to manufacture and increasing the complexity of the assembly process.
Innovation Solution
The use of lead plates instead of lead lines for insertion into the zero current transformer's central opening, which are then fixed using positioning portions, simplifies assembly and reduces the need for separate lead plates, thereby reducing the number of components and manufacturing time. Additionally, the lead plates are integrally formed with the metal plates constituting the power feeding lines, allowing for a more compact arrangement of the terminal block and relay unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lead lines are used for power feeding lines extending through the zero current transformer, then the electrical connection is established, but the assembly becomes difficult due to bending issues during insertion
Solution Approach 1:
The patent changes the physical form parameter of the power feeding lines from flexible lead lines to rigid lead plates. This parameter change eliminates the bending issue during assembly while maintaining electrical conductivity, as the lead plates can be directly inserted and fixed in position without deformation
Solution Approach 2:
The power feeding lines are segmented into distinct functional parts: lead plates for insertion and positioning, and metal plates for electrical connection. This segmentation allows each part to optimize its specific function - the lead plates for easy insertion and positioning, and the metal plates for reliable electrical connection
2Ease of operation
If lead plates are provided separately from metal plates, then the power feeding lines can be properly configured, but the number of components increases and welding time increases
Solution Approach 1:
The patent merges the lead plate and metal plate into a single integrally formed power feeding line component. This eliminates the need for separate assembly and welding operations, reducing both the number of components and manufacturing time while maintaining the proper configuration for power feeding
3Volume of moving object
If the terminal block and zero current transformer are arranged in an overlapping relationship, then the housing size is reduced, but the assembly complexity increases
Solution Approach 1:
The patent transitions from a planar arrangement to a three-dimensional overlapping arrangement of the terminal block and zero current transformer. This spatial reconfiguration in the vertical dimension reduces the horizontal footprint and overall housing size while the integral design of power feeding lines maintains assembly simplicity
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
This configuration enhances the ease of assembly, reduces the size of the housing, and decreases the time required for welding, resulting in a more efficient and compact power feeding control apparatus.
Implementation Method 1
The zero current transformer detects the leakage current based on unbalanced currents flowing through the power feeding lines
Data Source
Figure 1
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Figure 3A~3D
AI summary
A power feeding control apparatus includes a housing for accommodating at least a relay unit which opens and closes power feeding lines, a control circuit for controlling the relay unit, a leakage current detection circuit for detecting leakage current in the electric vehicle and a power supply circuit for generating a control electric power. The apparatus further includes a power source side connector and a vehicle side connector. The leakage current detection circuit includes a zero current transformer through which the power feeding lines extend and is configured to detect leakage current based on unbalanced currents flowing through the power feeding lines. Lead plates constitute a part of the power feeding lines and pass through a central opening of the zero current transformer, and the zero current transformer includes a positioning member molded within the central opening to fix the positions of the lead plates.