Service Plug Unit Rotary Lever Mechanism for Electric Car High Voltage Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power cutting-off systems for electric cars fail to maintain shielding performance during vehicle vibrations, leading to unintended power cutoffs and safety risks due to high voltage sparks and foreign substance penetration.
Innovation Solution
A service plug unit with a rotary lever and shielding member, designed to securely attach and detach from a device unit, ensuring high-voltage power is cut off at different times than the plug separation, maintaining earthing and sealing to prevent sparks and foreign substance ingress, while preventing arbitrary power cutoffs due to vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug is separated to cut off power, then power cutoff function is achieved, but sparks are generated due to high voltage causing safety problems
Solution Approach 1:
The plug is divided into two separate plugs: a high-voltage plug and an interlock terminal plug. This segmentation allows the interlock terminal to be disconnected before the high-voltage plug, eliminating sparks by ensuring the circuit is de-energized before physical separation occurs.
Solution Approach 2:
The interlock terminal is designed to separate before the high-voltage plug during the power cutoff process. This preliminary action ensures that the control circuit is opened first, de-energizing the system before the main power connection is broken, thereby preventing spark generation.
2Reliability
If the plug is secured to prevent arbitrary separation, then shielding performance is maintained, but unintended power cutoff is prevented
Solution Approach 1:
The rotary lever provides a dynamic locking mechanism that can be easily rotated to lock or unlock the plugs. This dynamic design maintains secure connection during vibration while allowing intentional power cutoff when needed, balancing stability with operational flexibility.
Solution Approach 2:
The rotary lever acts as an intermediary mechanism between the user's intent and the plug connection state. It provides a controlled interface that prevents accidental disconnection while allowing deliberate power cutoff, mediating between the need for security and ease of operation.
3Reliability
If earthing is maintained during vibration, then shielding performance is stable, but vibration resistance is improved
Solution Approach 1:
The rotary lever mechanism includes vibration-resistant features that dynamically adapt to maintain electrical contact. The design allows for controlled movement while maintaining stable earthing connection even during vehicle vibration, ensuring consistent shielding performance.
Data Source
AI summary
The inventive concept relates to a service plug unit capable of stably maintaining shielding performance even during vibration of a vehicle, safely cutting off high voltage/current power, and preventing an unintended power cut-off caused by an external force such as vibration, a device unit, and a power cutting-off system for use in an electric car and including the same.