Cable Guide for AC Charger with EMC and Assembly Optimization
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Solution Overview
Problem
Existing AC chargers for electric and hybrid vehicles face challenges in reducing size while maintaining electromagnetic compatibility (EMC), robustness, and water-tightness, and require complex assembly processes that increase manufacturing costs.
Innovation Solution
The AC charger design features a cable guide with parallel conductor receivers and alignment means to ensure correct positioning and routing of cables, a one-piece cable guide for simplified manufacturing, and a two-part housing with a PCB aligned in a common plane to reduce size and enhance robustness, while using reinforcement webs and specific channel configurations to improve EMC and water-tightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex assembly process is used to ensure precise cable positioning and EMC compliance, then the electromagnetic compatibility and positioning precision are improved, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The cable guide is pre-formed with precisely positioned conductor receivers and alignment features during manufacturing. This preliminary preparation of the cable guide structure eliminates the need for complex assembly operations, as cables automatically align and position themselves when inserted into the pre-configured guide channels and receiver slots.
Solution Approach 2:
The cable guide acts as an intermediary component between the housing and the cables/PCB. It mediates the positioning and routing of multiple conductors through its structured channels and receivers, ensuring EMC compliance and precise alignment without requiring complex direct assembly between housing and electrical components.
2Volume of stationary object
If the AC charger size is reduced to improve compactness, then the housing volume is decreased, but the EMC compliance and structural robustness may be compromised
Solution Approach 1:
The cable guide utilizes three-dimensional space efficiently within the compact housing by creating vertical channels and layered receiver arrangements. Conductors are routed through vertically stacked regions, allowing compact horizontal footprint while maintaining adequate separation distances for EMC compliance through clever use of the vertical dimension.
Solution Approach 2:
The cable guide structure employs nested arrangements where conductor receivers are positioned within confined spaces, and cables are routed through concentric or layered paths. This nesting allows multiple conductors to be accommodated in a compact volume while maintaining necessary spacing and shielding for EMC compliance.
3Adaptability or versatility
If multiple separate components are used for the cable guide to allow flexibility in cable routing, then the adaptability is improved, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The cable guide is designed as a universal component that accommodates multiple cable types and routing configurations through its modular channel system and array of conductor receivers. The same single-piece guide structure can handle different cable arrangements by utilizing its pre-formed channels and receivers, eliminating the need for multiple specialized components.
Solution Approach 2:
Multiple functional elements that would traditionally require separate components (cable channels, conductor receivers, alignment features, and structural supports) are merged into a single integrated cable guide component. This consolidation maintains cable routing flexibility through the combined functionality while dramatically simplifying manufacturing and assembly.
Data Source
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AI summary
The present invention relates to a cable guide for an AC charger, to an AC charger for an electric or hybrid vehicle, to a tool for the assembly of an AC charger and to a method of assembling an AC charger.