Charging Control Box Retainer for Secure Cable Coupling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrified vehicles require multiple charging cables for different charging environments, leading to economic burdens and issues such as heat generation and forced disconnection of charging cables, which can result in incomplete charging or safety hazards.
Innovation Solution
A control box with a first connector connected to an external power source and a second connector with varying terminal lengths, a controller to ensure complete coupling, and a retainer mechanism to prevent separation, ensuring safe and complete charging by only allowing power transmission when both connectors are fully coupled.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If charging cables are separated from the ICCB to allow replacement depending on charging environments, then adaptability to different charging types is improved, but the coupling reliability between charging cables and ICCB deteriorates
Solution Approach 1:
The controller performs preliminary detection of coupling status before initiating charging. The detection unit checks whether the connector is fully inserted into the coupling structure, and only when complete coupling is confirmed does the controller enable power transmission, preventing charging before proper connection is established
Solution Approach 2:
A coupling structure with detection mechanism serves as an intermediary between the charging cable and ICCB. This intermediary includes a detection unit that monitors coupling status and a controller that uses this information to control power transmission, ensuring reliable connection before charging commences
2Ease of operation
If charging is performed without confirming complete coupling, then ease of operation is improved, but harmful effects such as heat generation at the joint increase
Solution Approach 1:
The detection unit provides real-time feedback on coupling status to the controller. The controller continuously monitors whether the connector is fully inserted and uses this feedback to control the power transmission switch, enabling charging only when complete coupling is confirmed, thereby preventing heat generation from incomplete connections
3Ease of operation
If the connector structure allows easy insertion and removal, then ease of operation is improved, but the coupling force decreases making the connection vulnerable to external forces
Solution Approach 1:
The coupling structure is segmented into distinct functional zones: an insertion guide portion that facilitates easy insertion, a locking portion that provides secure coupling force, and a detection portion that monitors connection status. This segmentation allows the structure to provide both ease of operation and strong coupling force simultaneously
Data Source
AI summary
A control box for charging includes a second connector disposed at a first end of the control box and configured to be coupled to a first connector provided at a first end of a supply cable configured to be connected to an external power source. The control box includes a retainer configured to prevent separation of the first connector when the first connector and the second connector are completely coupled. A top of the control box is open at a position corresponding to the second connector and the retainer is inserted through the open top and moved up and down.