Protective Cap Geometry for Automated Charging Inlet Sealing
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Solution Overview
Problem
Large mobile machines require protection for their inlet receptacles from debris and moisture when not connected to a charging station, and existing solutions lack an automated mating mechanism.
Innovation Solution
A protective cap with a planar cap plate, a triangular shell, and a cap handle is designed for detachable mating with the inlet receptacle. The cap includes a pin boss cavity and is made of rigid polymer, allowing for automated mating and protection from contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the inlet receptacle is left exposed for automated charging operations, then the ease of operation and automated mating is improved, but the reliability of the electrical system deteriorates due to contamination from debris and moisture
Solution Approach 1:
The protective cap is pre-positioned on the inlet receptacle in a stored state, ready for automated attachment. The automated mating system performs the protective action in advance by automatically caping the receptacle when not in use, eliminating the need for manual intervention while maintaining protection against contaminants.
Solution Approach 2:
The system automatically manages its own protection needs through automated detection of the charging state and corresponding automated attachment or removal of the protective cap. The inlet receptacle effectively protects itself without requiring external manual intervention, resolving the contradiction between automated operation and reliability.
2Reliability
If a protective cap is added to the inlet receptacle, then the protection from contaminants is improved, but the device complexity increases due to additional components
Solution Approach 1:
The protective cap design merges multiple functions into a single integrated component: the cap body provides contamination protection, the cap handle enables automated grasping and attachment, and the overall structure is configured to mate with the inlet receptacle. This consolidation reduces the need for separate protective components while maintaining reliability.
3Ease of operation
If the protective cap is designed for automated mating, then the ease of operation is improved, but the manufacturing precision requirements worsen due to tight tolerances for automated alignment
Solution Approach 1:
The protective cap and inlet receptacle feature asymmetric triangular geometries with specific orientation requirements. The triangular configuration provides inherent alignment cues that guide automated mating systems, ensuring proper orientation while the asymmetric design allows for controlled tolerances that are easier to manufacture than symmetric precision fits.
Solution Approach 2:
The automated mating system is designed to operate from a single optimal approach angle and position, creating an equipotential mating state. The triangular shell and cap geometry are configured so that automated systems can achieve proper alignment through a standardized approach, simplifying the manufacturing precision requirements compared to multi-angle or multi-position mating systems.
Data Source
AI summary
A protective cap can be mated with an inlet receptacle of an electrical charging system on a mining machine. The protective cap is made of a non-conductive rigid material and can include a triangular shell extending from a planar cap plate. Extending from the cap plate opposite the triangular shell can be a cap handle including a flange and a standoff web to form one or more undercuts between the flange and cap plate. In an aspect, the cap handle is configured to be grasped by a mechanical gripper.