Replaceable High-Voltage Cable Cut-Out Housing With Shielded Isolation
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Solution Overview
Problem
The existing protective devices for high-voltage cables in electric vehicles require the entire cable to be exchanged when a cut-out fails, which is costly and labor-intensive.
Innovation Solution
A protective device with a housing that allows non-destructive detachment for exchanging only the defective cut-out, featuring a shielding element and contacts for connecting the cut-out and shielding conductor sections, enabling isolation of high-voltage components in fault scenarios without replacing the entire cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire high-voltage cable is exchanged when a cut-out fails, then the protective device reliability is restored, but the cost and labor intensity increase significantly
Solution Approach 1:
The protective device is segmented into a housing and an insert, where the insert containing the cut-out can be independently replaced. This allows only the defective cut-out to be exchanged while retaining the housing and other functional components, thereby restoring reliability without the need to replace the entire high-voltage cable, reducing both cost and labor intensity.
Solution Approach 2:
The cut-out is extracted as a separate replaceable component (insert) from the housing. When the cut-out fails, only this extracted component needs to be replaced, rather than replacing the entire cable assembly. This extraction principle directly addresses the contradiction by enabling targeted replacement that restores reliability while minimizing cost and effort.
2Reliability
If the entire high-voltage cable is exchanged when a cut-out fails, then the protective function is restored, but the time required for replacement increases
Solution Approach 1:
By segmenting the protective device into a permanent housing and a replaceable insert, the replacement process is streamlined to involve only the insert. This segmentation enables rapid replacement of the defective cut-out without the time-consuming process of replacing the entire cable assembly, thus restoring protective function while minimizing downtime.
Solution Approach 2:
The cut-out is extracted as a standalone replaceable component that can be quickly swapped out. This extraction allows for rapid replacement of only the defective part, significantly reducing the time required compared to replacing the entire cable, while still restoring the protective function effectively.
3Stability of the object's composition
If the housing is made permanently attached to the high-voltage-cable sections, then the structural stability is improved, but the ease of repair deteriorates
Solution Approach 1:
The housing is segmented into a stable outer structure that remains permanently attached to the high-voltage cable sections, and an inner insert that can be independently replaced. This segmentation maintains the structural stability of the overall assembly while enabling easy repair by allowing the insert to be removed and replaced without affecting the permanently attached housing.
Solution Approach 2:
The cut-out is extracted as a separate replaceable component within the housing. The housing itself remains permanently attached to maintain structural stability, while the extracted cut-out can be easily removed and replaced for repair purposes. This extraction principle resolves the contradiction by separating the permanent structural element from the replaceable functional element.
Data Source
AI summary
A protective device to be integrated into a high-voltage cable of a high-voltage on-board power supply includes a cut-out for interrupting at least one electrical conductor of the high-voltage cable in a fault scenario, a shielding element for forming a cable shield with a shielding conductor of the high-voltage cable, and a housing to be arranged between two high-voltage-cable sections of the high-voltage cable. In the housing, the cut-out and the shielding element are arranged, and the housing has contacts for connecting the cut-out to conductor sections of the at least one conductor and for connecting the shielding element to shielding-conductor sections of the shielding conductor. At least a part of the housing is capable of being non-destructively detached from the high-voltage-cable sections, in order to enable an exchange of at least the cut-out in the case of a defect of the cut-out.