Vehicle Charge Connector Alignment With Magnetic Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle charging systems require manual alignment of charge connectors, which is inconvenient and costly, and existing hands-free solutions like wireless charging have not gained widespread adoption due to infrastructure requirements and high costs.
Innovation Solution
A vehicle charging system that uses magnetic elements, gravity, and a spring-loaded mechanism for automatic alignment and connection of conductive charging elements, with a simple ground unit design that includes a locking mechanism and a cable spool for retractable cable management, allowing for hands-free conductive charging without complex alignment features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual coupling of charge connector is used, then charging system is simple, but operator convenience deteriorates
Solution Approach 1:
The charging system performs alignment and connection functions automatically without requiring manual operator intervention. The charge plug self-aligns with the charge port through the channel structure, and the locking mechanism automatically secures the connection, enabling the system to service itself during the charging process.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a simplified channel-based guidance structure. Instead of using multiple actuators and sensors for precise positioning, the angled surfaces and channel geometry guide the charge plug into proper alignment through passive mechanical constraints.
2Ease of operation
If hands-free charging with complex alignment features is implemented, then operator convenience improves, but infrastructure cost increases
Solution Approach 1:
The charging system is divided into distinct functional modules: a charge port assembly with integrated channel and locking mechanism, a separate charge plug with alignment features, and a cable management system. This segmentation allows each component to be manufactured independently using simple processes and assembled into the complete charging system.
Solution Approach 2:
The patent employs simple, inexpensive materials and construction methods for the charge port housing, channel structure, and locking mechanism. These components are designed to be cost-effective and easily replaceable, avoiding the need for expensive precision-machined parts or complex electronic alignment systems.
3Reliability
If locking mechanism is added for automatic connection, then connection reliability improves, but device complexity increases
Solution Approach 1:
The locking mechanism is integrated directly into the charge port housing structure, combining the functions of connection securing and structural support into a single unified component. This eliminates the need for separate locking devices and reduces the overall number of parts in the system.
Solution Approach 2:
The locking mechanism operates automatically upon insertion of the charge plug, using the insertion motion itself to trigger the locking action. The spring-loaded or cam-based mechanism engages the lock as the plug is pushed into place, requiring no additional actuators or control systems.
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
Enables cost-effective, hands-free conductive charging with reduced infrastructure costs, allowing for widespread adoption and improved user experience by automating the charging process without the need for complex alignment systems.
Implementation Method 1
The charge connector may further include one or more magnetic elements to attract the charge plug
Implementation Method 2
The actuator may be a solenoid
Data Source
AI summary
A vehicle charging station includes a shroud configured to guide a vehicle charge plug that is lowered from a vehicle toward a charge connector as the vehicle moves toward the charging station. The vehicle charge plug and the charge connector have contacts arranged on a connector face that is generally perpendicular to a surface on which the vehicle charging station rests.