Charging Plug Segmented Channels for High-Current Handling
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Solution Overview
Problem
Existing charging plugs for high-power electric vehicle charging stations are unwieldy due to thick, inflexible cables and limited cable exit angles, making them difficult to handle and maneuver during connection.
Innovation Solution
The charging plug design separates conductors into flexible and inflexible bundles, routing them through distinct channels to allow for a larger bending radius and a steeper cable exit angle, with the inflexible DC conductors positioned below signal lines to avoid crossover and enhance flexibility, and includes a handle formed by thin segments for improved usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high charging currents exceeding 250 A are transmitted, then power transmission efficiency is improved, but cable thickness and rigidity increase making the plug unwieldy
Solution Approach 1:
The cable is segmented into multiple conductors (positive, negative, signal, protective earth) with different flexibility requirements. Each conductor bundle is routed through separate channels within the plug housing, allowing optimized bending radii for each type while maintaining overall plug functionality for high current transmission
Solution Approach 2:
The plug design utilizes three-dimensional spatial arrangement with multiple routing channels at different angles. The cable exit angle is optimized by arranging conductor paths in three dimensions, allowing steep exit angles for flexible conductors while providing adequate bending radius for rigid power conductors through separate spatial paths
2Adaptability or versatility
If a steep cable exit angle is used, then cable routing flexibility is improved, but the plug becomes large and unwieldy
Solution Approach 1:
The plug housing is divided into multiple routing channels, each optimized for specific conductor types. Flexible conductors use channels with sharper bends and steeper exit angles, while rigid power conductors use channels with larger bending radii, allowing optimized cable exit angles without increasing overall plug volume
Solution Approach 2:
Different regions of the plug housing provide different geometric properties - some channels have sharp bends for flexible conductors while others have gentle curves for rigid conductors. This local optimization allows steep cable exit angles in specific areas without making the entire plug large and unwieldy
3Device complexity
If conductors with different bending radii are routed together, then routing simplicity is improved, but conductor flexibility and cable management deteriorate
Solution Approach 1:
Conductors are segmented into separate bundles based on flexibility requirements. Rigid power conductors (positive and negative) are routed through dedicated channels with larger bending radii, while flexible conductors (signal and protective earth) use separate channels with sharper bends, optimizing each type without complicating overall routing
Solution Approach 2:
The routing problem is solved by extracting rigid power conductors from the general conductor group and providing them with dedicated routing paths. This separation removes the constraint that would force all conductors to use the same bending radius, allowing optimal routing for each conductor type
Data Source
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AI summary
The invention provides a charging plug (10) for a charging station with the following features: The charging plug (10) comprises a contact carrier (11) and a housing shell (12); the housing shell (12) has a first channel and a second channel; the first channel and the second channel open into the contact carrier (11); and the first channel is more sharply curved than the second channel. The invention further provides a corresponding charging station.