Touch-safe interface contact resistance measurement

Solution Overview

Problem

Existing methods struggle to accurately measure the transition resistance of touch-proof interfaces between high-voltage components, especially when these interfaces are insulated and difficult to access.

Innovation Solution

A procedure involving the use of measuring sensors inserted through touch-proof measurement windows in the insulation, allowing for the direct measurement of transition resistance between high-voltage components without damaging the insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If insulation is applied to protect high-voltage components, then safety against accidental contact is improved, but accessibility for resistance measurement deteriorates

Engineering Contradiction:

Improvesafety protectionVSAvoidaccessibility for resistance measurement

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The insulation is segmented by creating localized measuring windows that penetrate the insulating layer. These windows provide targeted access points for measurement sensors while preserving the overall insulation integrity and safety protection of the high-voltage components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Measuring sensors are introduced as intermediary elements that pass through the insulation via measuring windows. These sensors enable electrical contact resistance measurement by establishing measurement circuits through the insulated interface without compromising the insulation's safety function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Difficulty of detecting and measuring

If measuring sensors are inserted through insulation, then measurement accessibility is improved, but insulation integrity deteriorates

Engineering Contradiction:

Improvemeasurement accessibilityVSAvoidinsulation integrity

Core Design Contradiction:

Difficulty of detecting and measuringVSReliability

Solution Approach 1:

The insulation is segmented by creating localized measuring windows that penetrate the insulating layer. These windows provide targeted access points for measurement sensors while preserving the overall insulation integrity and safety protection of the high-voltage components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The measuring windows are pre-formed in the insulation during the manufacturing process before the component is assembled. This preliminary action ensures that the insulation structure is prepared in advance to accommodate measurement sensors without requiring damage or modification after assembly, thereby maintaining insulation integrity.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If traditional measurement methods are used on insulated interfaces, then safety is maintained, but measurement accuracy deteriorates

Engineering Contradiction:

ImprovesafetyVSAvoidcontact resistance measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

Measuring sensors are introduced as intermediary elements that pass through the insulation via measuring windows. These sensors enable electrical contact resistance measurement by establishing measurement circuits through the insulated interface without compromising the insulation's safety function.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The measurement approach substitutes direct physical access to the interface with a sensor-based measurement system that operates through the insulation. This replacement enables accurate electrical measurements while maintaining the mechanical integrity and safety of the insulated connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables accurate and non-destructive measurement of transition resistance, even in insulated high-voltage interfaces, thereby improving the reliability of high-voltage system connections.

Implementation Method 1

an electrical signal is passed through the interface via the first and second sensors

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP4305431B1Method for detecting a contact resistance of a touch-safe interface, and interface

Publication Date: 2025.04.09 LISA DRAXLMAIER GMBH

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AI summary

The present invention relates to a method for detecting a contact resistance (106) of a touch-safe interface (100) between a first high-voltage component (102) and a second high-voltage component (104), the interface (100) being protected in a touch-safe manner by an insulation (116). A first measuring probe (112) is introduced into a first touch-safe measuring window (114) of the insulation (116) provided on a first face of the interface (100) and is placed onto a first conductor (108) of the first high-voltage component (102). A second measuring probe (118) is introduced into a second touch-safe measuring window (120) provided on a second face of the interface (100) and is placed onto a second conductor (110) of the second high-voltage component (104). An electrical signal (124) is passed through the interface (100) via the first measuring probe (112) and the second measuring probe (118), and between the first measuring probe (112) and the second measuring probe (114) a resulting electrical variable (126) is measured at the interface (100), the contact resistance (106) being determined using the signal (124) and the electrical variable (126).