Spring Interlock for High-Voltage Connectors
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Solution Overview
Problem
Existing high-voltage arrangements for motor vehicles, such as pulse-controlled inverters, face challenges in ensuring that power electronics are only live when the cover is closed, as prior systems require complex sensor systems to de-energize the electronics when the cover is removed for maintenance, posing a risk of contact with high-voltage components.
Innovation Solution
A cost-effective and low-maintenance system utilizing a spring device with first and second spring elements to block the high-voltage mating connector when the cover is not installed, allowing the cover to be easily recognized as open and ensuring the power electronics are only live when the cover is closed, with the second spring element delaying cover removal to allow time for power electronics to switch off.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex sensor systems are used to detect open cover and de-energize power electronics, then safety is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex sensor systems with a simple mechanical spring device that physically blocks the high-voltage mating connector when the cover is removed. The spring element provides a mechanical interlock that prevents connector insertion unless the cover is properly installed, eliminating the need for electronic sensors and control systems while maintaining safety.
Solution Approach 2:
The spring device automatically engages and disengages based on the cover position. When the cover is installed, the spring is compressed and releases the blocking function, allowing connector insertion. When the cover is removed, the spring automatically returns to its blocking position, providing self-regulating safety without external control systems.
2Reliability
If sensors and control systems are implemented to ensure power electronics are switched off when cover is removed, then safety is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs a simple, inexpensive spring element and mechanical blocking structure instead of expensive sensor systems and control electronics. The mechanical interlock uses basic components like springs and blocking elements that are cost-effective to manufacture and assemble, significantly reducing production costs while maintaining the safety function.
3Ease of operation
If the cover can be quickly removed for maintenance, then ease of operation is improved, but safety risk increases due to potential contact with live power electronics
Solution Approach 1:
The spring device is pre-configured to automatically engage the blocking function when the cover is removed, preventing connector insertion before any potential contact with live power electronics can occur. This preliminary mechanical action ensures that even if maintenance personnel quickly remove the cover, the high-voltage connector cannot be connected, eliminating the safety risk.
4Ease of operation
If no mechanical blocking mechanism is used, then ease of operation is improved, but reliability deteriorates due to inability to prevent connector insertion with cover removed
Solution Approach 1:
The spring element acts as an intermediary mechanical block between the cover position and the connector insertion capability. When the cover is removed, the spring physically intervenes to prevent connector insertion. When the cover is installed, the spring is compressed and withdraws the blocking function, allowing normal operation. This intermediary mechanism seamlessly links cover position to connector availability.
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 solution eliminates the need for complex sensors and ensures the power electronics are only live when the cover is closed, providing a safe and efficient mechanism for maintenance while allowing sufficient time for the power electronics to be de-energized during cover removal.
Implementation Method 1
a spring device with at least one first spring element. The first spring element is arranged to be depressed by the mounted cover. If the cover is not mounted, the first spring element blocks the insertion of the high-voltage mating connector.
Data Source
AI summary
The invention relates to a high-voltage arrangement (1), preferably for a motor vehicle, comprising a housing (2), a high-voltage plug (4) arranged on the housing (2) for the insertion of a high-voltage mating plug (5), a cover (3) that can be mounted on the housing (2) and dismounted, and a spring device (6) comprising at least one first spring element (10) which, when the cover (3) is not mounted, blocks the high-voltage mating plug (5) from being inserted into the high-voltage plug (6), and said cover (3), when mounted, pushing said first spring element (10) down such that the high-voltage mating plug (5) may be inserted into the high-voltage plug (4).