Wireless High-Voltage Interlock Switch for Simpler EMC Shielding

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Solution Overview

Problem

Current high-voltage interlock systems in inverters and high voltage boxes are complex, incorporating extra PCBs and pigtail harnesses, leading to EMC issues and mechanical switch degradation, and require robust safety measures to prevent user access to charged components.

Innovation Solution

A wireless detection method using a Hall effect sensor circuit paired with a magnet, integrated into a PCB, to detect the presence of a cover or connector, ensuring safe access by deactivating or discharging internal components before access is allowed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional mechanical switches or contacts are used to detect access cover removal, then the system can detect when the cover is removed, but the system becomes less robust due to environmental factors and degradation

Engineering Contradiction:

Improverobustness of detection systemVSAvoidcomplexity of mechanical switch system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical switches or contacts with a wireless Hall effect sensor system. The Hall effect sensor detects the position of a magnet mounted on the access cover without physical contact, eliminating mechanical wear and degradation issues while maintaining reliable detection of cover removal status.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnet as an intermediary element mounted on the access cover. This magnet interacts with the Hall effect sensor through non-magnetic material walls, enabling detection without direct mechanical contact and improving system robustness against environmental factors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If extra PCBs and pigtail harnesses are incorporated into the interlock system, then the system can provide high-voltage interlock functionality, but assembly complexity and EMC issues increase

Engineering Contradiction:

Improvesafety of high-voltage interlockVSAvoidcomplexity of PCB and harness assembly

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical interlock systems with a wireless Hall effect sensor-based detection system. This eliminates the need for extra PCBs and pigtail harnesses, reducing assembly complexity while maintaining high-voltage interlock safety functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent integrates the Hall effect sensor directly into the existing PCB, merging the detection function with the existing circuit board. This eliminates the need for separate detection PCBs and pigtail harnesses, simplifying the overall assembly while maintaining interlock safety.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If mechanical switches or contacts are used for access detection, then the system can control access to internal components, but the system requires adding more components which increases assembly complexity

Engineering Contradiction:

Improvecontrolled access to internal componentsVSAvoidnumber of additional components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces mechanical switches with a wireless Hall effect sensor system that detects access cover removal. This reduces the number of additional components required while maintaining controlled access functionality through electronic detection rather than mechanical switching.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts the detection function from the mechanical switch system and implements it through a wireless Hall effect sensor. This removes the need for additional mechanical components and their associated assembly complexity while preserving the access control capability.

Inventive Principle:

Principle #2Taking out (Extraction)

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

The system simplifies assembly, reduces EMC issues, and enhances safety by minimizing exposure to high voltage components through controlled access, using a magnet and sensor configuration.

Implementation Method 1

a wireless detection method using a Hall effect sensor circuit paired with a magnet that detects if a cover or connector is removed

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentUS12453021B2Wireless high voltage interlock switch

Publication Date: 2025.10.21 VITESCO TECHNOLOGIES USA LLC

AI summary

An access assembly for a high voltage box or inverter which reduces the associated risk of exposure to charged components, such as high voltage power electronics, where an interlock is required. The access is limited so that the system may deactivate some functionality, and/or internal devices are discharged to allow safe access. The access assembly includes a wireless detection method using a sensor circuit paired with a magnet that detects if a cover or connector is removed. The magnet is mounted to the cover or connector. This detection may be made through walls of non-magnetic material, which avoids the incorporation of extra components such as PCBs or a pigtail harness, enables a much simpler EMC shielding by avoiding unwanted openings, and simplifies assembly by reducing required operations and processes. The access assembly may be used for applications where controlled access is required for installation or service of power electronic products.