Touch Protection Cover Positioning for Module Connectors
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Solution Overview
Problem
Existing module connectors in battery systems and energy systems face challenges in ensuring electrical safety while maintaining accessibility and reducing manufacturing costs, as conventional touch protection covers often suffer from incorrect positioning and increased waste due to imprecise mounting.
Innovation Solution
An electrically insulating touch protection cover with a positioning section that includes a protective collar and a positioning section with inwardly facing support surfaces, allowing the connection member to serve as a reference point for precise positioning, thereby ensuring correct alignment and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional touch protection covers are used without a positioning section, then the mounting process is simpler, but incorrect positioning and displacement occur leading to reduced electrical safety and increased waste
Solution Approach 1:
The connection member serves as its own positioning reference through the inwardly facing support surfaces, eliminating the need for external positioning fixtures or complex alignment procedures. The support surfaces are designed to automatically align with the connection member's geometry, enabling self-positioning during assembly.
Solution Approach 2:
The positioning section with support surfaces is pre-configured on the touch protection cover to establish correct positioning before the actual mounting operation. This preliminary positioning structure ensures that when the cover is attached to the connection member, it is already correctly aligned, preventing subsequent displacement.
2Ease of manufacture
If conventional touch protection covers are mounted without precise positioning features, then manufacturing costs increase due to waste, but adding positioning sections increases device complexity
Solution Approach 1:
The touch protection cover is segmented into distinct functional sections: the protective collar for safety coverage, the contacting chamber for receiving the connection member, and the positioning section with support surfaces for accurate alignment. This segmentation allows each part to be optimized independently while maintaining overall simplicity.
Solution Approach 2:
The positioning section introduces localized geometric features (inwardly facing support surfaces) only where needed for positioning, rather than complicating the entire cover structure. The support surfaces are strategically placed to contact specific portions of the connection member, providing precision without unnecessary complexity elsewhere in the design.
3Manufacturing precision
If the positioning section uses the connection member as a reference point, then positioning accuracy improves, but the design becomes more specific and less adaptable to different connection members
Solution Approach 1:
The inwardly facing support surfaces are designed with geometric characteristics that can accommodate various connection member types and sizes. By using the connection member's own geometry as the reference, the positioning system becomes universally applicable across different connection members without requiring custom positioning features for each variant.
Data Source
AI summary
A touch protection cover for a connection member of a module connector. The touch protection cover includes a housing section which forms a protective collar for the connection member, a contacting chamber which is surrounded by the protective collar and which is configured to receive the connection member, and a positioning section which extends within the contacting chamber. The positioning section includes at least one support surface which is offset from the protective collar and faces inwardly with respect to the contacting chamber and which is configured to abut against the connection member. The positioning section allows the connection member to be used as a reference point when attaching the touch protection cover.