Terminal Block Conductive Core Arc Deflection
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Solution Overview
Problem
Electric traction vehicles with permanent magnet motors face destruction due to uncontrolled electric arcs formed when insulation fails, leading to short circuits between terminals, which cannot be stopped even when the vehicle is in motion, causing sudden blocking of the axles.
Innovation Solution
A terminal block with intermediate conductive cores electrically connected to the ground, deflecting potential short circuits towards the ground and allowing for fault detection, thereby preventing damage to the electrical machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating partitions are used to separate terminals, then the risk of electric arc between terminals is reduced, but overheating can break the insulating partitions and create short circuits
Solution Approach 1:
A conductive core electrically connected to ground is introduced as an intermediary element between the insulating partition and the terminals. When insulation fails due to overheating, the conductive core provides a safe path for electric arc to discharge to ground rather than between terminals, thus protecting against short circuits while maintaining the benefits of insulating partitions.
Solution Approach 2:
The invention converts the harmful effect of electric arc (which would cause destruction) into a beneficial protective mechanism. By providing a controlled discharge path through the conductive core to ground, the electric arc is redirected away from critical components, transforming a destructive phenomenon into a safety feature that indicates insulation failure while preventing catastrophic damage.
2Reliability
If contactor is opened to isolate motor from inverter, then electrical fault protection is provided, but electric arc can still form and be maintained during vehicle motion
Solution Approach 1:
The conductive core acts as an intermediary ground reference that provides a safe discharge path for electric arc within the terminal block, independent of the contactor state. This ensures that even when the contactor is open and the motor is isolated from the inverter, any electric arc formed will be safely directed to ground through the conductive core rather than causing uncontrolled damage.
3Reliability
If terminal block protects against electric arc, then machine destruction is prevented, but fault detection capability must be maintained
Solution Approach 1:
The conductive core provides a measurable reference to ground that enables fault detection systems to monitor the electrical state of the terminal block. By maintaining a known electrical relationship with ground, the system can detect anomalies such as insulation failures through changes in electrical parameters, providing feedback that allows both protection and diagnostics to function simultaneously.
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
The solution effectively prevents partial or total destruction of the electrical machine by redirecting electric arcs to ground, enabling fault detection and reducing the risk of short circuits between phase terminals, secondary terminals, or connection plates, thus protecting the machine and allowing continued operation.
Implementation Method 1
an electric arc is then likely to form, in particular between two of the terminals of the terminal block
Implementation Method 2
at least one intermediate conductive core, which is arranged within each intermediate insulating partition and which is configured to be electrically connected to an electrical ground of the electrical machine
Data Source
Figure 1
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Figure 3
AI summary
The invention discloses a terminal block, an electric machine comprising such a terminal block and a vehicle comprising such an electric machine. The terminal block (3) for an electrical machine has at least two phase terminals (10, 12, 14). The terminal block comprises at least two connection plates (56, 58, 60). For each connection board, means (68, 70, 72) are used for fixing one of the phase terminals and a secondary terminal (18, 20, 22) for supplying electrical energy to and/or receiving electrical energy emitted by related phase terminals. At least one insulating intermediate partition (44, 46) of the terminal block is arranged between the connection plates. According to the invention, the terminal block (3) comprises at least one conductive intermediate core (96, 98), which is arranged within each insulating intermediate partition (44, 46) and which is configured to be electrically connected to an electric mass of the electric machine.