Battery Cover Charging Connector Layout for Easier Assembly
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Solution Overview
Problem
Existing working vehicles with on-board charging power source connectors face challenges such as cumbersome assembly processes, increased man-hours, and spatial occupation due to the oblique downward direction of the connector, making inspection and maintenance difficult.
Innovation Solution
The on-board charging power source connector is integrated with the battery cover, allowing assembly outside the connector case, and is fixed by welding to a reinforcing plate, with the connector case positioned on the vehicle's end, reducing spatial occupation and facilitating easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the on-board charging power source connector case is fixed to the counterweight by fixing screws inside the connector case, then the connector can be securely mounted, but the assembly work becomes cumbersome and the number of man-hours increases
Solution Approach 1:
The connector case is pre-fixed to the battery cover during battery cover assembly before the final vehicle assembly. This preliminary action allows the connector case to be securely mounted while enabling workers to access and assemble components from the outside of the connector case, significantly reducing assembly man-hours and improving productivity
2Ease of operation
If the connector case is positioned with the connecting portion directed obliquely downward to the center area, then the connector can be connected, but the space occupied in height direction and vehicle width direction becomes large
Solution Approach 1:
The connector case is repositioned from the traditional oblique downward orientation to the end portion of the battery cover, utilizing the lateral dimension of the battery cover. This dimensional change allows the connector to be positioned at the extreme end, minimizing the space occupied in both height direction and vehicle width direction while maintaining connection functionality
3Ease of repair
If the battery cover is opened for maintenance, then access to internal components is possible, but the on-board charging power source connector is covered and inspection work becomes difficult
Solution Approach 1:
The on-board charging power source connector case is extracted from the traditional mounting position and repositioned to the end portion of the battery cover. This extraction and repositioning ensures that the connector case remains externally accessible even when the battery cover is opened for maintenance, allowing inspection work to be performed without obstruction while still enabling access to internal battery components
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
This configuration reduces assembly time and saves space around the connector case, enabling easier inspection and maintenance while preventing water intrusion and ensuring the connector remains within the vehicle's swing radius.
Implementation Method 1
The on-board charging power source connector case fixing portion is fixed to a reinforcing plate that is fixed to an inner back surface of the battery cover
Data Source
AI summary
Provided is a working vehicle that reduces the number of assembling man-hours of an on-board charging power source connector, and realizes the saving of a space around an on-board charging power source connector case. The working vehicle includes: an on-board charging power source connector; and an on-board charging power source connector case on which the on-board charging power source connector is mounted, and allows the charging cable to pass therethrough. The on-board charging power source connector case is disposed on a right side end portion of a battery cover. The on-board charging power source connector case is fixed to a reinforcing plate fixed to an inner back surface of the battery cover at an on-board charging power source connector case fixing portion.