Sensor-Controlled Power Connector for Arc-Flash Protection

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Solution Overview

Problem

High voltage DC connectors face safety hazards and reduced lifespan due to arc-flash risks during connection and disconnection, and existing connectors are limited by sacrificial contact areas and lack integrated safety features like local control and shock protection.

Innovation Solution

An electronic controller integrated with the connector, featuring sensors for secure connection detection, remote and local control, and circuit breaker functionality, which enables safe power transmission only when the connection is secure and provides protection against overcurrent, arc-faults, and shock hazards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If power is transmitted continuously through the connector, then power delivery efficiency is improved, but safety hazards increase due to arc-flash risks during connection and disconnection

Engineering Contradiction:

Improvepower delivery efficiencyVSAvoidarc-flash risks

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The connector performs preliminary actions by detecting connection status through sensors before enabling power transmission. The secure connection detection mechanism verifies proper mating of plug and socket contacts before the power switch closes, ensuring connections are established under controlled conditions rather than allowing continuous power delivery that could cause arc-flash during unplanned disconnection or improper insertion

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The connector implements feedback control through sensors that continuously monitor connection status and provide signals to the power switch control circuitry. This feedback mechanism allows the system to adjust power transmission based on real-time connection conditions, closing the power switch only when secure connection is confirmed and opening it when connection is lost, thereby preventing arc-flash hazards while maintaining efficient power delivery during valid connections

Inventive Principle:

Principle #23Feedback

2Ease of manufacture

If sacrificial contact areas are used in connectors, then manufacturing simplicity is improved, but connector lifespan is reduced due to wear and degradation

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidconnector lifespan

Core Design Contradiction:

Ease of manufactureVSDuration of action of stationary object

Solution Approach 1:

The connector replaces mechanical wear-based contact systems with electronically controlled power switching. Instead of relying on sacrificial contact areas that physically degrade from repeated make/break cycles, the invention uses sensors to detect connection status and electronically controls power transmission through a power switch, eliminating the need for physical contact wear and significantly extending connector lifespan while maintaining manufacturing simplicity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If integrated safety features are added to connectors, then safety protection is improved, but device complexity increases

Engineering Contradiction:

Improvesafety protectionVSAvoidconnector complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The connector merges safety detection and power control functions into an integrated unit. The sensor for detecting secure connection and the power switch for controlling power transmission are combined within the connector housing, allowing safety features to be implemented without proportionally increasing overall device complexity. The merged design enables coordinated operation of detection and control functions while maintaining a compact, manageable structure

Inventive Principle:

Principle #5Merging (Combining)

4Object-affected harmful factors

If power transmission is delayed until secure connection is confirmed, then safety is improved, but connection time is increased

Engineering Contradiction:

ImprovesafetyVSAvoidconnection time

Core Design Contradiction:

Object-affected harmful factorsVSLoss of time

Solution Approach 1:

The connector implements a rapid detection mechanism that quickly verifies secure connection status through the sensor system. Rather than implementing prolonged verification procedures, the sensor rapidly detects contact presence and quality, and the control circuitry quickly processes this information to enable power transmission. This rushing through the verification process minimizes the time delay while ensuring safety through reliable detection of secure connection before power is transmitted

Inventive Principle:

Principle #21Skipping (Rushing through)

Data Source

PatentUS11831109B2Electrical connector with integrated electronic controlled power switch or circuit breaker safety device

Publication Date: 2023.11.28 CISCO TECHNOLOGY INC

AI summary

In one embodiment, and apparatus includes an electrical socket for connection with an electrical plug, a sensor for identifying a secure connection between the electrical socket and the electrical plug, and an electronic controller electrically coupled to the electrical socket and comprising a power input for receiving power. The electronic controller is operable to transmit power to the electrical socket upon receiving a signal from the sensor identifying the secure connection between the electrical socket and the electrical plug and shut off or turn on power to the electrical socket upon receiving an external input to the electronic controller. A method is also disclosed herein. The apparatus and method provide an electronic controlled power switch or circuit breaker safety device.