Protective cap for the inlet socket of the charging system

Abstract

A protective cap (150) can mate with an inlet socket (122) of a charging system (100) on a mining machine. The protective cap (150) is made of a non-conductive rigid material and may include a triangular shell (154) extending from a flat cap plate (152). Extending from the cap plate (152) opposite the triangular shell (154) may be a cap handle portion (156), which includes a flange (180) and a spacer web (182) to form one or more undercuts (184) between the flange (180) and the cap plate (152). In one aspect, the cap handle portion (156) is configured to be gripped by a mechanical clamp (200).

Description

Technical Field

[0001] This patent disclosure generally relates to a protective cap for an inlet socket of a charging system, and more specifically, to a protective cap that can be adapted to automatically engage with a complementary inlet socket. Background Technology

[0002] Large mobile machines used in industries such as mining, construction, or agriculture are equipped with large power units to deliver megawatts of power suitable for the heavy loads encountered during operation. While large mobile machines operating in such industries traditionally use internal combustion engines to generate the required power, some machines have recently been configured to operate electrically. Electric large mobile machines may include electric motors that convert electricity into power to operate the machinery's mechanical implements. To provide a power source, the electric motors are operatively associated with one or more rechargeable batteries that accumulate and store electrical energy and are located on the mobile machine.

[0003] Rechargeable batteries may be depleted during operation and may require periodic recharging from another power source, such as the power grid. To recharge the rechargeable battery, a large mobile machine may be operatively associated with a charging system including an electrical connector that operatively connects the mobile machine to a power source. The electrical connector may include an inlet socket typically located on the mobile machine, and a charging plug that can detachably mate with the inlet socket. The charging plug may be operatively associated with a charging station capable of delivering several megawatts of power to the charging system. This disclosure relates to a means for protecting the inlet socket from contamination by debris and moisture when not plugged into a charging station and during charging. Summary of the Invention

[0004] In one aspect, this disclosure describes a protective cap configured for detachably mating to an inlet socket of a charging system. The protective cap includes a flat cap plate, a triangular housing connected to the cap plate and extending from the cap plate in a first direction, and a cap handle connected to the cap plate and extending from the cap plate in a second direction opposite to the triangular housing. The triangular housing may define and enclose a pin boss cavity to receive the pin boss when mating with a pin boss of the inlet socket. The cap plate, the triangular housing, and the cap handle may be made of a rigid polymer and may be integrally connected together.

[0005] In another aspect, this disclosure describes an electrical connector for a charging system, the connector comprising an inlet socket and a protective cap that can be mated together relative to an insertion axis. The inlet socket includes a triangular pin boss having a plurality of pin prongs disposed within a socket recess. The triangular pin boss is defined by a triangular boundary wall of the inlet socket and is separated from the triangular boundary wall by a socket channel. The protective cap is detachably mated to the inlet socket and includes a cap plate oriented perpendicular to the insertion axis when mated to the inlet socket. Extending perpendicularly from the cap plate in a first direction is a triangular housing integrally connected to the cap plate. The triangular housing may have a peripheral wall having a first planar panel, a second planar panel, and a third planar panel arranged triangularly relative to each other and configured for sliding mating with the socket channel of the inlet socket. To grip the protective cap and engage or disengage it from the inlet socket, the protective cap may include a cap handle integrally connected to the cap plate and projecting from the cap plate in a second direction opposite to the first direction. Attached Figure Description

[0006] Figure 1 This is a perspective view of a mobile mining tractor configured for electric operation using one or more rechargeable batteries that can be connected to a charging system.

[0007] Figure 2 This is a front plan view of the inlet socket on the mobile mining tractor, which is part of the electrical connection associated with the charging system.

[0008] Figure 3 This is a front perspective view of an embodiment of a protective cap, characterized by a thin-walled triangular housing that can fit into an inlet socket when the socket is not connected to a charging plug of a charging system.

[0009] Figure 4 This is a rear perspective view of the protective cap, showing the pin boss cavity spatially defined by the triangular shell.

[0010] Figure 5 This is a side elevation view of the protective cap, showing the cap handle configured in an ergonomic way for gripping.

[0011] Figure 6 This is a perspective assembly diagram of an embodiment of the protective cap that is operably fitted into the inlet socket via a mechanical clamp. Detailed Implementation

[0012] Referring now to the accompanying drawings, where possible, the same reference numerals will denote the same elements, Figure 1The diagram illustrates a charging system 100 for a large mobile mining tractor 102. Such a mining tractor 102 (also referred to as a mining dump truck) is used to transport mined or excavated materials (including mineral ores and soil) at various locations on the work site during mining operations, and the material payload of the mining tractor 102 can be on the order of several tons. To accommodate the mined material, the mining tractor 102 may include a tipping body 104, which is pivotally attached to and can be articulated relative to a machine frame 106. The tipping body 104 can be tilted pivotally relative to the machine frame 106 to unload the payload when needed. To enable the mobile mining tractor 102 to travel at various locations on the mining site, the machine frame 106 may be supported on a plurality of rotatable wheels 108 or similar propulsion devices (such as continuous tracks) that contact and apply traction to a working surface 110 of the mining site. However, while this document discloses a charging system 100 for a mobile mining tractor 102, aspects of this disclosure will be applicable to other large electric machines that require charging systems capable of delivering power in the megawatt range.

[0013] To accommodate an operator, the mining tractor 102 may include an onboard operator station 112 positioned on the machine frame 106 at a location providing visibility throughout the mining site. Due to the large size of the mining tractor 102, the onboard operator station 112 may be located several meters above the work surface 110 and accessible via ladders and walkways 114. In possible embodiments, the mining tractor 102 may be configured for remote operation, where the machine is operated remotely by a non-onboard operator, or for autonomous operation, where the machine operates without significant human intervention.

[0014] According to this disclosure, the mining tractor 102 can be configured for electric operation, wherein an electric motor 116 delivers power to rotatable wheels 108 to propel the machine. To provide power to the electric motor 116, the mining tractor 102 may include one or more rechargeable batteries 118 located on the machine frame 106. The batteries 118 store and provide a fixed amount of electrical energy to the electric motor 116, but may be depleted during operation and require periodic recharging from an advanced power source such as the mains grid. A charging system 100 is included on the mining tractor 102 for operably connecting to the mains grid and delivering recharged power to the batteries 118.

[0015] The charging system 100 may be designed to deliver several megawatts of power, which may be necessary to power a large mobile mining machine 102 that may require a large amount of power during operation due to its physical size and payload weight. An example of a suitable charging system for megawatt charging is the system proposed under SAE standard J3271, also known as a megawatt charging system (“MCS”), but aspects of this disclosure can be applied to other charging systems. For connection to the mining tractor 102, the charging system 100 may include an electrical connector 120, which may be a multi-component arrangement including an inlet socket 122 disposed on the machine frame 106, the inlet socket being capable of mating with a charging plug 124 electrically connected to a charging station 126 via a flexible power cable 128.

[0016] Reference Figure 2 The inlet socket 122 can serve as a female component of the electrical connection 120 and can have a geometric arrangement that facilitates mating with the male configuration of the charging plug. In embodiments of the MCS J3271 charging system, the geometric arrangement of the inlet socket 122 can be characterized by a generally triangular outline to facilitate alignment when mating with the charging plug.

[0017] For example, the inlet socket 122 may include a triangular boundary wall 130 that protrudes outward from and is perpendicular to the planar socket substrate 132. The socket substrate 132 may be square in shape, with its outer perimeter being larger than the three-sided triangular boundary wall 130. The triangular boundary wall 130 may be a thin-walled construction and may define an inwardly positioned hollow socket recess 134 that geometrically conforms to the shape of the triangular boundary wall 130. A triangular pin boss 136 is disposed within the socket recess 134, which may be separated from the triangular boundary wall 130 by a gap or a socket channel 138. The socket channel 138 is spatially located between the triangular boundary wall 130 and the triangular pin boss 136 and geometrically conforms to both the triangular boundary wall and the triangular pin boss, such that the boundary wall 130 defines the socket channel 138, which in turn defines the pin boss 136.

[0018] In an embodiment, the triangular geometry of the inlet socket 122 may be an equilateral triangle with three vertices having the same angle. Furthermore, the triangular boundary wall 130, the socket channel 138, and the triangular pin boss 136 may define an insertion axis 140 (indicated by a circular cross) extending perpendicularly to the substrate 132 of the inlet socket 122, and may be equidistantly positioned around said insertion axis. The insertion axis 140 may spatially correspond to the centroid of the triangular profile of the inlet socket 122. The outer triangular boundary wall 130 and the inner triangular pin boss 136 may extend approximately the same dimensional distance from the planar substrate 132 and terminate at their front edges flush with each other.

[0019] To establish electrical connection with the charging station, the triangular pin boss 136 may include a plurality of pin sockets 142 disposed on the front of the pin boss. As an example, the pin sockets 142 may include a larger circular power socket 144 located at each vertex of the triangular pin boss 136, and smaller data sockets 146 disposed in the body of the triangular pin boss and generally surrounded by the power sockets. The larger power sockets 144 may transmit high-voltage, high-current power and / or serve as electrical ground, while the smaller data sockets 146 may transmit lower-power data signals.

[0020] To enclose the inlet socket 122 when not in use with a charging plug and to protect it from debris or moisture, and to prevent accidental contact with the internal conductive material, refer to Figure 3 and 4 A protective cap 150 may be provided. The protective cap 150 may be a monolithically formed single-piece structure made of a non-conductive polymer, such as a moldable thermoplastic. Furthermore, the protective cap 150 may have a generally triangular geometry (e.g., an equilateral triangle) to engage and be detachably held by an inlet socket of a corresponding shape. For reference purposes, the insertion axis 140 may be described as being generally aligned with and passing through the centroid defined by the triangular geometry of the protective cap 150.

[0021] For example, to mate with and enclose an inlet socket, the protective cap 150 may have a flat cap plate 152, which, for reference purposes, is oriented perpendicular to the insertion axis 140 when mate with the inlet socket. A triangular housing 154 may be integrally connected to the cap plate 152 and extend vertically from the cap plate in a first direction. For operation of the protective cap 150, a cap handle 156, sized for gripping by a human operator or mechanical device, may extend from the cap plate 152 in a second direction opposite to the first direction of the triangular housing 154.

[0022] To provide the geometric profile of the protective cap 150, the triangular housing 154 may include a three-sided peripheral wall 160 having a first planar panel 162, a second planar panel 164, and a third planar panel 166. The three-sided peripheral wall 160 may extend in dimensions together with the cap plate 152, which may have the same geometric profile as the triangular housing 154. The first, second, and third planar panels 162, 164, 166 may be generally rectangular in shape and may be arranged as an equilateral triangle around the insertion axis 140. A corresponding number of rounded bevels 168 may be located at each vertex of the triangular housing 154 to interconnect the multiple planar panels at secondary edges. One of the main edges of each planar panel may form an integrally abutted proximal edge 170 of the peripheral wall 160 of the cap plate 152, while a second of the main edges of the planar panel forms a distal edge 172 axially spaced from the cap plate 150 relative to the insertion axis 140.

[0023] The first, second, and third planar panels 162, 164, and 166 can all be thin-walled structures, such that the peripheral wall 160 encloses and defines an internal hollow space referred to as a pin boss cavity 174. The pin boss cavity 174 may geometrically correspond to the triangular shell 154. A passage to the pin boss cavity 174 is provided at the open distal edge 172, while the cap plate 152 is connected at the proximal edge 170 of the peripheral wall 160, which laterally encloses the pin boss cavity 174 at that location. In an embodiment, an elastic or flexible washer 176 may be attached to the inwardly exposed surface of the cap plate 152 that is exposed to the pin boss cavity 174. The flexible washer 176 may be a compound such as foam rubber having a triangular shape similar to the cap plate 152, which is adhered to the cap plate by an adhesive backing.

[0024] Reference Figure 1 When the protective cap 150 is aligned with the insertion axis 140 and fitted into the inlet socket 122, the triangular pin boss 136 can be received into a correspondingly shaped pin boss cavity 174 defined by the triangular housing 154. Furthermore, the peripheral wall 160 of the triangular housing 154, composed of thin-walled planar panels 162, 164, and 166, can be nested or received in a correspondingly shaped socket channel 138 provided between the triangular boundary wall 130 and the triangular pin boss 136, forming a sliding engagement with it. This sliding engagement between the socket channel 138 and the peripheral wall 160 allows the inlet socket 122 to retain the protective cap 150 until sufficient removal force is applied to the cap handle 156. The gasket 176 can contact and resiliently press against the holes of the plurality of pin ports 142 of the inlet socket 122 to provide an additional seal against debris and moisture.

[0025] Reference Figure 3 and 5The handle portion 156 can be ergonomically configured for gripping and manipulating the protective cap 150. For example, the handle portion 156 may include a flange 180 connected to and spaced apart from the cap plate 152 by a spacer web 182. The flange 180 may be generally flat or planar and may be oriented parallel to the cap plate 152. The spacer web 182 may extend perpendicularly between the flange 180 and the cap plate 152, thereby spatially spaced these structures and providing sufficient length for the handle portion 156 to be effectively gripped during use. The flange 180 may be dimensionally larger than the spacer web 182, such that it extends beyond and overlays the offset web to define one or more recesses or undercuts 184 located between the spaced-apart flange 180 and the cap plate 150. The wider flange 180 and the narrower spacer 182 connected thereto provide the cap handle portion 156 with a knob-like feature having an undercut 184, thereby allowing fingers to be inserted behind the flange 180 when attempting to grasp and pull the cap handle portion 156.

[0026] The crown handle portion 156 may be centrally positioned relative to its protruding cap plate 152, but in possible embodiments, the crown handle portion may be offset relative to one edge of the proximal edge 170 of the cap plate 152. In embodiments, the crown handle portion 156, including the flange 180 and the spacer belly 182, may be generally triangular in shape to correspond to the triangular profile of the protective cap 150, but in other embodiments, the crown handle portion may have other geometries or configurations. In embodiments where the triangular shell 154 of the protective cap is an equilateral triangle with equal sides and vertex angles, the flange 180 of the crown handle portion 156 may also be an equilateral triangle.

[0027] The protective cap 150 may include other features to facilitate mating with an inlet socket of an electrical connector. For example, to seal the inlet socket against debris and moisture, and to help retain the protective cap 150 within the inlet socket when mating with it, one or more O-ring recesses 186 may be provided in the outer surface of the triangular housing 154. The location of the O-ring recesses 186 may coincide with the proximal edge 170, and the O-ring recesses may extend around and define three planar panels 162, 164, and 166 of the peripheral wall 160. The O-ring recesses 186 may have a three-sided geometric cross-section to receive an O-ring or another irregular seal made of a relatively elastomeric or elastic material, such as a polymer. The depth of the O-ring recesses 186 may be selected such that a portion of the O-ring will protrude beyond the outer surface of the triangular housing 154. When the protective cap 150 is mated with... Figure 2 When the inlet socket 122 shown is in place, the O-ring can deform against the inner surface of the triangular boundary wall 130 and elastically apply sealing pressure against the inner surface, which also helps to frictionally hold the protective cap 150 within the socket recess 134.

[0028] In another example, the protective cap 150 may include another sealing configuration, such as a spherical seal or gasket made of an elastic compressible material (such as foam rubber) that linearly defines a triangular housing 154 to seal the boundary wall of the inlet socket. The spherical seal may include a rounded sphere protruding from the outer surface of the peripheral wall 160, which can contact and press against the boundary wall 130 of the inlet socket 122 when mating with the protective cap 150.

[0029] In another example, the protective cap 150 may include one or more protruding, thin, flexible sealing fins that extend outward from and define the outer surface of the triangular housing 154. The sealing fins may be thin-walled flexible structures that extend linearly around a peripheral wall 160 (e.g., near the proximal edge 170) and may be perpendicular or angled relative to the surface of the peripheral wall. In embodiments, a plurality of flexible fin seals extend parallel to each other from the peripheral wall. The sealing fins may contact and flexibly rub against the inner surface of the boundary wall during insertion, thereby sealing the inlet receptacle. In various embodiments, the seals and / or gaskets may be different separate structures attached to the protective cap 150, or may be integrally formed as part of the protective cap via a co-molding process to achieve a relative difference in elastic properties between the polymer seals and the relatively rigid material of the rest of the protective cap.

[0030] Reference Figure 5 In this embodiment, to facilitate insertion of the protective cap 150 into the inlet socket, the distal edge 172 of the triangular housing 154 may be oriented at an angle 188 relative to the insertion axis 140. For example, the angle 188 tilts the distal edge 172 relative to the planar cap plate 152 such that the distal edge is not truly perpendicular to the insertion axis 140, and one of the three rounded bevels 168 is established as the leading edge of the triangular housing 154. During engagement of the protective cap 150 with the inlet socket, the leading edge of the distal edge 172 is initially received into the spatially larger socket recess. During further insertion of both structures, subsequent sliding contact between the distal edge 172 and the boundary wall aligns the triangular profile of the peripheral wall 160 with the triangular geometry of the inlet socket. Due to the angle 188 of the distal edge 172, the protective cap 150 can tolerate a certain degree of misalignment with the inlet socket during insertion.

[0031] In this embodiment, to further facilitate the insertion of the protective cap 150, the triangular housing 154 may taper slightly inward relative to the insertion axis 140. For example, the first, second, and third planar panels 162, 164, and 166 of the peripheral wall 160 may be connected along a tapered axis 189 that deviates from a vertical or right angle relative to the cap plate 152. The tapered axis 189 may be formed by tilting the first, second, and third planar panels 162, 164, and 166 relative to the cap plate 152 or by gradually decreasing the thickness of the peripheral wall 160 connecting the proximal edge 170 of the cap plate 152 and the distal edge 172 spaced therebetween.

[0032] Industrial applicability

[0033] Reference Figure 6 In one aspect, the protective cap 150 in the embodiments can be configured for cooperative operation with the mechanical clamp 200. The mechanical clamp 200 can be constructed as a mechanical linkage having a plurality of extended clamping fingers 202 or grippers that can be moved relative to each other by hydraulic, pneumatic, or electric actuation. In the illustrated embodiment, the mechanical clamp 200 can be configured as a dual-finger angle clamp, wherein two clamping fingers 202 are interconnected at a common hinge joint 204 serving as a fulcrum. The clamping fingers 202 can be pivotally hinged relative to each other to enclose and grip and / or open and release objects between their respective distal finger tips 206. In another example, the mechanical clamp 200 can have a parallel design with common extended clamping fingers 206 that can move together and separate parallel to each other. In order to move the mechanical gripper 200 and spatially align it with the inlet socket 122 and the protective cap 150, the mechanical gripper can be operated as an end effector attached to the distal end of the robot arm.

[0034] In the example where the mechanical clamp 200 is designed as a dual-finger configuration, the cap handle 156 of the protective cap 150 can have a corresponding geometric arrangement to facilitate operative interaction with the two clamp fingers 202. In the illustrated embodiment of the cap handle, the flange 180 and the offset web 182 can be generally rectangular in shape and oriented such that the flange and the offset web extend generally between the relative rounded slopes 168 of the first planar panel 162 and the peripheral wall 160. The rectangular flange 180 can be wider than the correspondingly narrower offset web 182, such that a recess or undercut 184 is again formed between the end cap 152 and the parallel overhanging edges of the flange 180.

[0035] During operation, the mechanical clamp 200 moves to align with the handle portion 156 of the protective cap 150. The mechanical clamp 200 can move adjacent to the handle portion 156 such that the distal finger tip 206 extends beyond the flange 180 and can move into the undercut 184 between the flange and the cap plate 152 to physically contact the handle portion 156. The mechanical clamp 200 can be described as forming a clamp relative to the handle portion 156, wherein the flange 180 is surrounded and gripped by the clamp fingers 202. The distal finger tip 206 may be formed with barbs or hooks to facilitate clamping. Subsequently, the mechanical clamp 200 can move the protective cap relative to the insertion axis 140 to engage or disengage the protective cap 150 and the inlet socket 122.

[0036] The protective cap 150 is designed to interact operably with the mechanical clamp 200 to advantageously automate the charging system 100 during the recharging process. For example, refer to [reference needed]. Figure 1 The access socket 122 may be located on the machine frame 106 in a position not easily accessible to the operator. For example, in the case of a large haulage truck, such as the mobile mining hauler 102, which is an onboard operator station accessible via ladders and walkways 114, it may be inconvenient for the operator to disassemble the machine to recharge the battery 118. Similarly, if the mobile mining hauler 102 is an autonomous machine, it may be possible to use the charging system 100 for the recharging process without an operator present.

[0037] Therefore, aspects of the protective cap 150 can be designed to facilitate operative interaction with the mechanical gripper 200 operated by the robot. For example, the stiffness of the polymer material of the protective cap 150 provides sufficient strength to apply and transmit forces from the mechanical gripper 200 during mating and disengagement. The relative stiffness of the polymer material also helps resist deformation or displacement of the protective cap 150 during insertion into the socket channel 138, which could lead to misalignment or improper mating and allow the protective cap 150 to loosen and disengage from the inlet socket 122.

[0038] In another example, the cap handle 156 may have an irregular shape or may be associated with additional features to facilitate the alignment of the protective cap 150 with the inlet socket along the insertion axis 140. For example, the cap handle 156 may be adjacent to one or more geometrical notches 210 disposed in the planar surface of the cap plate 152 and shaped to uniquely geometrically engage with the distal finger tip 206, achieving a fixed or predetermined spatial alignment between the protective cap 150 and the mechanical clamp 200. Kinematics can then be used to determine and adjust the relative spatial position of the mechanical clamp 200 with respect to the inlet socket 122 and / or the insertion axis 140 to ensure the correct mating orientation of the protective cap 150. The cap handle 156 has a triangular shape... Figure 3In one embodiment, the protective cap 150 can be operatively gripped by a mechanical clamp 200 having three gripper fingers 202, and the irregular triangular shape provides a unique geometric fit between these structures.

[0039] In another example, the flange 180 of the cap handle 156 may be positioned flush with the plane of the cap plate 152, rather than protruding beyond the cap plate. In such an embodiment, the geometric notch 210 may still be provided in the planar surface of the cap plate 152 as an undercut, which allows the gripper fingers 202 to extend around and grasp the flange 180, which is otherwise flush with the cap plate. Positioning the flange 180 flush with the planar cap plate 152 eliminates any structural protrusions from the protective cap 150 that might otherwise inadvertently come into contact with or impact passing objects.

[0040] In another example, the protective cap 150 may include clearly visible positioning features 212 disposed on the cap plate 152. Positioning features 212 may be, for example, contrasting dots or circles, and may be arranged in a unique pattern or arrangement. A robot operatively associated with the mechanical gripper 200 may have machine vision capabilities to detect the pattern of the positioning features 212, thereby aiding in the alignment of the mechanical gripper 200 and the protective cap 150. Other features that may be included in the protective cap 150 to facilitate alignment and mating may include textured surfaces, locating pins, etc.

[0041] In one embodiment, the protective cap 150 may be a separate component and may be completely separate from the inlet socket 122. Therefore, the protective cap 150 can be held by the mechanical clamp 200 during the recharging process and will not shift relative to the automatic charging system 100. In other embodiments where the charging system 100 is not automated, the protective cap 150 may be attached or fastened relative to the inlet socket 122 by, for example, a key chain.

[0042] It should be recognized that the foregoing description provides examples of the disclosed systems and techniques. However, other embodiments of this disclosure are contemplated that may differ in detail from the foregoing examples. All references to this disclosure or examples thereof are intended to refer to the specific examples discussed at the time and are not intended to imply any limitation on the scope of this disclosure in a more general sense. All distinctions and adverse statements regarding certain features are intended to indicate that such features are not preferred, but are not intended to completely exclude such features from the scope of the invention unless otherwise indicated.

[0043] Unless otherwise indicated herein, the descriptions of value ranges herein are intended solely as a shorthand for referring to each independent value falling within the range, and each independent value is incorporated into the specification as if described separately herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or clearly contradicted by the context.

[0044] In the context of describing the invention (especially in the context of the following claims), the terms “a” and “an” and “the” and “at least one” or the terms “one or more” and similar references should be interpreted to cover both the singular and the plural, unless otherwise stated herein or explicitly contradicted by the context. The use of the term “at least one” followed by a list of one or more items (e.g., “at least one of A and B” or “one or more of A and B”) should be interpreted to indicate the selection of one item (A or B) from the list or any combination of two or more of the list items (A and B), unless otherwise stated by the context or explicitly contradicted by the context.

[0045] Therefore, as permitted by applicable law, this disclosure includes all modifications and equivalents to the subject matter set forth in the appended claims. Furthermore, unless otherwise indicated herein or clearly contradicted by the context, this disclosure covers any combination of the foregoing elements and all their possible variations.

Claims

1. A protective cap (150) configured for detachably mating with an inlet socket (122) of a charging system (100), the protective cap comprising: A triangular shell (154) including a peripheral wall (160) having a first planar panel (162), a second planar panel (164) and a third planar panel (166) integrally connected together, the peripheral wall (160) enclosing the pin boss cavity (174). A cap plate (152), integrally connected to the triangular shell (154) near its side edge (170), the cap plate (152) being oriented perpendicular to the first planar panel (162), the second planar panel (164), and the third planar panel (166); and The cap handle portion (156) is integrally connected to the cap plate (152) and protrudes from the cap plate opposite to the triangular shell (154).

2. The protective cap (150) according to claim 1, wherein the cap handle portion (156) includes a flange (180) connected to the cap plate (152) by a spacer web (182) to define an undercut between the flange (180) and the cap plate (152).

3. The protective cap (150) according to claim 2, wherein the flange (180) corresponds to the triangular shell (154) in a triangular shape.

4. The protective cap (150) according to claim 2, wherein the flange (180) is rectangular in shape.

5. The protective cap (150) according to claim 1, wherein a plurality of rounded bevels (168) connect the first planar panel (162), the second planar panel (164) and the third planar panel (166).

6. The protective cap (150) according to claim 1, wherein the peripheral wall (160) is tapered inward relative to the pin boss cavity (174) between the proximal edge (170) and the distal edge (172).

7. The protective cap (150) according to claim 1, wherein the protective cap (150) is made of a rigid plastic material.

8. The protective cap (150) according to claim 7 further includes an elastic sealing member disposed on the outside of the peripheral wall (160) to define the triangular shell (154).

9. The protective cap (150) according to claim 8, wherein the resilient sealing member is at least one of an O-ring, a spherical seal, and a finned seal.

10. An electrical connector (120) defined along an insertion axis (140) for a charging system (100), comprising: An inlet socket (122) includes a triangular pin boss (136) disposed within a socket recess (134) and including a plurality of pin ports (142). The triangular pin boss (136) is defined by a triangular boundary wall (130) separated from it by a socket channel (138). The triangular pin boss (136) defines a centroid that is substantially aligned with the insertion axis (140) of the inlet socket (122). as well as A protective cap (150) detachably matable to the inlet socket (122), the protective cap (150) comprising: Cap plate (152), which is oriented perpendicular to the insertion axis (140) when engaged; A triangular housing (154) including a peripheral wall (160), the peripheral wall being integrally connected to the cap plate (152) and extending from the cap plate in a first direction, the peripheral wall (160) having a first planar panel (162), a second planar panel (164), and a third planar panel (166) arranged triangularly relative to each other and configured for sliding engagement with the socket channel (138); and The cap handle portion (156) is integrally connected to the cap plate (152) and protrudes from the cap plate in a second direction opposite to the first direction.

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