Bayonet Locking Mechanism for Electric Vehicle Charging Connector
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Solution Overview
Problem
Conventional connector parts for electric vehicle charging sockets require complex assembly processes due to screw-based attachments, which complicates the connection between the housing and base parts, necessitating a simpler and more reliable attachment method.
Innovation Solution
A connector part design featuring a bayonet-style form-fitting mechanism with positive-locking elements on both the housing and base parts, allowing for easy assembly and secure engagement through rotational alignment and locking elements, along with a sealing mechanism to prevent moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections are used to attach the base part to the housing part, then a reliable connection is achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The connection mechanism is segmented into distinct functional elements: insertion for initial engagement, rotation for locking, and positive-locking elements for securing. This segmentation allows each step to be simple and intuitive, reducing overall assembly complexity while maintaining reliability
Solution Approach 2:
The connection process transitions from a static screw-fastening approach to a dynamic bayonet-style connection that involves insertion followed by rotation. This dynamic approach enables quick assembly and disassembly while ensuring a reliable locked connection through the rotational engagement of positive-locking elements
2Device complexity
If a simple attachment method is used to reduce assembly complexity, then assembly becomes easier, but connection reliability may be compromised
Solution Approach 1:
The insertion step serves as a preliminary action that pre-aligns the base part with the housing part and engages the positive-locking elements in a ready position. This preliminary engagement ensures that subsequent rotation will reliably lock the connection, maintaining reliability while keeping the overall process simple
Solution Approach 2:
The complex multi-step screw fastening process is extracted and replaced with a simplified two-step bayonet connection. The essential locking function is retained through the positive-locking elements, while unnecessary complexity is removed, achieving both simplicity and reliability
3Ease of manufacture
If modular design with interchangeable base parts is implemented to reduce component variety, then manufacturing costs decrease, but assembly precision requirements increase
Solution Approach 1:
The bayonet-style connection mechanism with positive-locking elements is designed as a universal interface that can accommodate different base part configurations. The standardized insertion and rotation process works consistently across various base part designs, reducing manufacturing costs through component interchangeability while maintaining adequate assembly precision through the self-aligning nature of the bayonet connection
Data Source
AI summary
A plug connector part (1), in particular for transferring a charging current to charge an electric vehicle, comprises a housing part (2), which has a plug opening (21) for plugging in a counter-plug connector part (5) for connection to the plug connector part (1), and a base part (3), which can be connected to the housing part (2), and at least one contacting device (31) for making contact with the counter-plug connector part (5). Here, there is provision that the housing part (2) has at least one first form-fitting element (24) and the base part (3) has at least one second form-fitting element (32), wherein the base part (3) can be applied to the housing part (2) in a mounting direction (M) for connection to the housing part (2) and, to fix the connection, can be rotated relative to the housing part (2) in a direction of rotation (S) directed around the mounting direction (M) in such a way that the at least one first form-fitting element (24) of the housing part (2) and the at least one second form-fitting element (32) of the base part (3) come into form-fitting engagement with one another. In this way, a plug connector part is made available which allows simple mounting of the plug connector part and at the same time ensures a firm connection between the housing part and the base part.