Bi-Stable EV Charging Connector for Heavy Cable Handling

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Solution Overview

Problem

High-power liquid cooled charging cables for electric vehicles become stiff and heavy, making them difficult to handle, and charging connectors are vulnerable to damage, while existing robotic systems are expensive and potentially hazardous.

Innovation Solution

A charging arrangement featuring a bi-stable mechanics system with an actuation device that automatically connects and disconnects charging connectors, allowing for user-friendly and cost-effective high-power charging without the need for complex robotic systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If liquid cooled charging cables are used for high-power charging, then charging cable can carry high current (500A at 1000V) effectively, but the charging cable becomes very stiff and heavy making it difficult to handle

Engineering Contradiction:

Improvecharging powerVSAvoidhandling ease

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The charging system is divided into two separate components: a stationary charging device with connector and cooling system, and a mobile vehicle with receptacle. This segmentation eliminates the need for long, heavy liquid-cooled cables while maintaining high-power charging capability through inductive energy transfer.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the mechanical connection system (physical charging cable with liquid cooling) with an inductive coupling system using magnetic fields. The primary winding in the charging device generates a magnetic field that induces current in the secondary winding in the vehicle, eliminating the need for heavy liquid-cooled cables.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Power

If liquid cooled charging cables are used for high-power charging, then charging cable can carry high current (500A at 1000V) effectively, but the charging cable weight increases becoming too much for ordinary person to handle

Engineering Contradiction:

Improvecharging powerVSAvoidcharging cable weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If charging connectors are made robust for high-power charging, then charging reliability is improved, but charging connectors become vulnerable to damage if dropped or handled incorrectly

Engineering Contradiction:

Improvecharging reliabilityVSAvoidconnector damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary between the charging device and the vehicle. The primary winding generates a magnetic field that couples inductively with the secondary winding, allowing energy transfer without direct mechanical contact between connectors.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Object-affected harmful factors

If robotic systems are used to handle charging connectors, then connector handling safety is improved, but system cost increases and potential danger to humans remains

Engineering Contradiction:

Improvehandling safetyVSAvoidsystem complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12090870B2Charging arrangement and method for charging an electrical vehicle

Publication Date: 2024.09.17 ABB E-MOBILITY BV

AI summary

A charging arrangement includes an electrical vehicle and a charging device configured for charging the electrical vehicle with electrical energy, where the electrical vehicle includes a first charging connector, and the charging device includes a second charging connector configured for connecting with the first charging connector, a bi-stable mechanics to which the second charging connector is attached and which is configured for holding the second charging connector in two stable equilibrium positions, whereby in one stable equilibrium position the second charging connector is connected to the first charging connector and the other stable equilibrium position the second charging connector is unconnected to the first charging connector and an actuation device configured for moving the second charging connector between the two stable equilibrium positions.