Vehicle High-Voltage Plug Connector Vibration Resistance
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Solution Overview
Problem
Existing high-voltage plug connectors for vehicle on-board electrical systems lack sufficient vibration resistance, making them unsuitable for reliable contact with vehicle motors.
Innovation Solution
A high-voltage plug connector design featuring a protective housing made of metal, such as aluminum, with an engagement ridge and channel for secure attachment, combined with sealing elements to enhance vibration resistance and electromagnetic compatibility, and a simplified assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing high-voltage plug connector designs are used, then the connector can be assembled and function electrically, but the vibration resistance is insufficient for reliable vehicle motor contact
Solution Approach 1:
The connector is divided into distinct functional components: a plug casing containing contact parts, a separate protective housing made of metal, and an engagement mechanism with ridge and channel. This segmentation allows each component to be optimized independently for its specific function while maintaining overall vibration resistance.
Solution Approach 2:
The connector combines different materials with complementary properties: plastic for the plug casing (providing insulation and structural support), metal for the protective housing (providing electromagnetic shielding and enhanced mechanical strength), and elastomeric sealing elements (providing vibration damping and sealing). This composite construction resolves the contradiction by integrating materials that collectively deliver both reliability and manageable complexity.
2Reliability
If a metal protective housing is added to improve vibration resistance and electromagnetic compatibility, then the connector's durability improves, but the device complexity increases
Solution Approach 1:
The metal protective housing performs multiple functions simultaneously: it provides electromagnetic shielding for compatibility, structural reinforcement for vibration resistance, and houses the engagement mechanism for secure connection. This multi-functionality reduces the need for separate components, thereby managing complexity while improving reliability.
Solution Approach 2:
The protective housing merges the functions of electromagnetic shielding, structural protection, and engagement mechanism housing into a single integrated component. This consolidation reduces the number of separate parts and assembly steps, managing complexity while achieving improved durability and electromagnetic compatibility.
3Reliability
If an engagement ridge and channel system is implemented for secure attachment, then the plug connector achieves higher vibration resistance, but the manufacturing complexity increases
Solution Approach 1:
The engagement ridge and channel are pre-formed as integral features of the plug casing and protective housing respectively, rather than being assembled from separate components. This preliminary formation during molding or machining simplifies the final assembly process while ensuring precise alignment and stable connection for vibration resistance.
Data Source
AI summary
The present disclosure relates to an electrical plug connector, such as a high-voltage plug connector, for a vehicle. The plug connector comprises a plug with a plug casing, one or more electrical contact parts accommodated in the plug casing, a socket with a socket casing, and a protective housing at least partly encasing the plug casing and the socket casing. The protective housing comprises an attachment flange in a connection area reaching up to a counterpart connectable thereto. An engagement ridge of the protective housing is spaced apart from the attachment flange in the longitudinal direction L of the plug connector and at least positively engages in an engagement channel of the plug casing.