Charging Socket Flap Design for Industrial Trucks
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Solution Overview
Problem
Existing charging sockets for industrial trucks face challenges in protecting electrical connectors from unintentional opening due to harsh conditions, such as compressed air or water, and require easy access while maintaining effective protection.
Innovation Solution
A charging socket design featuring spring-loaded flaps that open inward when a charging plug is inserted, with offset rear walls and a kinked construction to reduce the impact of cleaning jets, and a locking mechanism accessible during closure to ensure secure operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring-loaded flaps are used to protect the charging socket, then protection against unintentional opening is improved, but access to the charging socket becomes more difficult
Solution Approach 1:
Instead of having flaps that open outward, the patent employs flaps that open inward when a charging plug is inserted. This inverted approach allows the flaps to remain closed and protective during normal operation, yet automatically opens when needed for charging, thus resolving the contradiction between protection and accessibility.
2Reliability
If small spring-loaded flaps open inwards, then protection is maintained, but the flaps may open during cleaning with compressed air or water jet
Solution Approach 1:
The patent introduces a kinked construction with offset rear walls that adds a dimensional offset to the flap structure. This offset positioning creates a geometric barrier that prevents cleaning jets from directly acting on the flap's pivot point, thereby preventing unintended opening while maintaining the protective function.
3Reliability
If the charging socket is located behind a hinged door, then protection is improved, but sufficient space must be provided for the door to swing open
Solution Approach 1:
Instead of using a single hinged door that requires swing space, the patent segments the protective cover into multiple small flaps that pivot independently. This segmentation eliminates the need for large swing space while maintaining effective protection, as each flap can move independently without requiring the clearance of a full door.
4Object-affected harmful factors
If flaps are constructed with two wall sections and offset rear walls, then resistance to cleaning jets is improved, but device complexity increases
Solution Approach 1:
The patent modifies the geometric parameters of the flap structure by introducing offset rear walls and kinked constructions. These parameter changes create a more complex shape that inherently resists cleaning jets, while the complexity is managed through consistent geometric patterns that can be manufactured efficiently.
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
The design effectively prevents unintentional opening of the charging flap while allowing easy access for charging, providing enhanced protection against water and compressed air while maintaining usability.
Implementation Method 1
At least one spring element pre-tensions the flaps into a closed position
Implementation Method 2
A jet of compressed air or water directed at the charging socket, when aimed at the opening of the charging socket, essentially strikes the recessed rear walls of the flaps, thereby preventing or significantly reducing the moment that would open the flap
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
Charging socket with an electrical connector for a charging plug, comprising a frame with an opening to the electrical connector and a pair of flaps pivotably arranged on pivot axes parallel to each other, wherein at least one spring element biases the flaps into a closed position, each flap having a base wall and a back wall, the back walls being offset relative to an imaginary plane of the opening in the frame in the direction of the electrical connector.