Vehicle Connector Assembly With Two-Step High-Voltage Disconnection
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Solution Overview
Problem
High-voltage connectors used in electric vehicles face electrical hazards due to the short interval between the separation of power and interlock terminals, leading to potential sparks and accidents when quickly separated, and external forces can inadvertently cut power, causing dangerous situations.
Innovation Solution
A connector assembly with an intermediate locking mechanism that restricts the lever's rotation, maintaining an intermediate locked state where interlock terminals are separated and power terminals remain connected, allowing for a controlled two-step disconnection process to ensure electrical safety by securing a sufficient interval between terminal separations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If connectors are quickly separated to improve operation speed, then separation time is reduced, but the interval between interlock terminal separation and power terminal separation becomes too short causing electrical hazards
Solution Approach 1:
The disconnection process is segmented into two distinct stages: first the interlock terminals separate while power terminals remain connected, then after a controlled interval, the power terminals separate. This segmentation ensures that the separation process is controlled and safe, preventing simultaneous separation that could cause electrical hazards.
Solution Approach 2:
The interlock terminal separation is performed as a preliminary action before power terminal separation. By first separating the interlock terminals and maintaining power connection for a controlled interval, the system ensures that any necessary electrical disconnection procedures are completed before the actual power terminals separate, preventing spark generation.
2Measurement precision
If interlock terminal is installed at CPA to detect separation state, then monitoring capability is improved, but external force can inadvertently separate interlock terminal causing false power cut
Solution Approach 1:
The interlock terminal is extracted from the CPA structure and integrated directly into the connector assembly. This separation of functions allows the interlock terminal to be mechanically protected within the connector housing while still providing accurate separation state detection, eliminating the vulnerability of having it exposed at the CPA where it could be affected by external forces.
Solution Approach 2:
The interlock terminal is positioned and protected within the connector structure before separation occurs. The connector housing and internal structure provide mechanical protection to the interlock terminal, cushioning it against external forces that could cause inadvertent separation or false detection signals.
3Ease of manufacture
If general high-voltage lever connector structure is used, then manufacturing simplicity is maintained, but interval between power terminal and interlock terminal separation cannot be secured causing sparks
Solution Approach 1:
The connector incorporates a dynamic two-stage disconnection mechanism where the lever movement is divided into distinct phases. As the lever rotates, it first disengages the interlock terminals while maintaining power terminal contact, then after a controlled interval, it disengages the power terminals. This dynamic control sequence prevents simultaneous separation and eliminates spark generation while maintaining manufacturing simplicity.
Data Source
AI summary
A connector assembly enables electrically safe disconnection and separation because it is possible to secure an interval between the point of time of separation of interlock terminals and the point of time of separation of power terminals when connectors are separated. The connector assembly can implement two steps of cutting power after restricting a lever in a locked state and then completely disconnecting connectors by additionally operating the lever by including an intermediate locking mechanism that restricts the lever for disconnecting connectors in a state in which interlock terminals of two connectors are separated from each other but power terminals of the two connectors are in contact with each other to disconnect and separate female and male connectors.