Vehicle Power Connector Layout for Spark-Free Reversible Mating
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Solution Overview
Problem
Existing electrical connectors for vehicles lack efficient power transmission and heat dissipation, often resulting in unreliable connections and potential sparking during assembly.
Innovation Solution
The electrical connector design features a plug with multiple power pins and a signal pin, where negative power pins are longer than positive power pins and signal pins, positioned to prevent sparking by grounding first, and a socket with passageways extending from multiple sides to allow for secure and reversible connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple power pins are used for power transmission, then power transmission reliability and heat dissipation efficiency are improved, but device complexity increases
Solution Approach 1:
The power transmission function is segmented into multiple independent power pins (at least two positive power pins and two negative power pins). Each pin handles a portion of the total current, distributing the electrical load and improving reliability. If one pin fails, others can maintain connectivity. This segmentation also enhances heat dissipation by spreading thermal load across multiple contact points.
Solution Approach 2:
The connector is designed with multi-functionality by integrating both power transmission and signal communication functions into a single connector structure. The signal pins and power pins coexist in the same housing, allowing simultaneous transmission of electrical power and data signals, reducing the need for separate connectors and overall system complexity.
2Object-affected harmful factors
If negative power pins are made longer to ground first, then sparking is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The negative power pins are designed with greater length than positive power pins and signal pins, creating a preliminary structural condition that ensures ground connection occurs first during insertion. This preliminary design of differential lengths automatically establishes the correct connection sequence (ground first, then power and signal) without requiring active control mechanisms, preventing sparking through pre-configured geometry.
Solution Approach 2:
The connector employs asymmetric pin length design where negative power pins are intentionally made longer than positive power pins and signal pins. This asymmetric configuration creates a built-in mechanism for controlled connection sequencing, ensuring that the grounding path is established before other electrical connections, thereby preventing short circuits and sparking during plug insertion.
3Adaptability or versatility
If passageways extend from multiple sides of socket housing, then connection versatility is improved, but device complexity increases
Solution Approach 1:
The socket housing incorporates passageways that extend from multiple sides (at least two adjacent sides) of the housing, adding spatial dimensionality to the connection capability. This allows the plug to be inserted from different directions, providing connection versatility for various mounting configurations and cable routing options without requiring multiple separate connectors.
Data Source
AI summary
A movable object includes a body, one or more propulsion units carried by the body and configured to effect movement of the movable object, and an electrical plug for power and signal transmission. The electrical plug includes at least one signal pin configured to communicate signal, a plurality of power pins configured to transmit electrical power, and a plug substrate configured to support the at least one signal pin and the plurality of power pins. The plurality of power pins include at least one power pin having a first polarity and at least one power pin having a second polarity opposite to the first polarity. The one or more propulsion units are provided with electrical energy via the electrical plug. The plurality of power pins and the at least one signal pin include a first set of power pins and signal pins, and a second set of power pins and signal pins. The first set and the second set are disposed symmetrically opposite to each other on the plug substrate, and the second set is provided in a row with the first set.