Charging Socket Flap Design for Industrial Trucks

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

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

VSEngineering 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

Engineering Contradiction:
Improveprotection against unintentional openingVSAvoidaccess to charging socket
Core Design Contradiction:
ReliabilityVSEase of operation

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.

Inventive Principle:
Principle #13The other way round (Inversion)

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

Engineering Contradiction:
Improveprotection of electrical contactsVSAvoidopening during cleaning
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

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.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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

Engineering Contradiction:
Improveprotection of electrical connectorVSAvoidspace for door swing
Core Design Contradiction:
ReliabilityVSArea of stationary object

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.

Inventive Principle:
Principle #1Segmentation

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

Engineering Contradiction:
Improveresistance to compressed air or water jetVSAvoidflap construction
Core Design Contradiction:
Object-affected harmful factorsVSDevice complexity

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.

Inventive Principle:
Principle #35Parameter changes

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

Methodology Applied
Scientific EffectSpring force: Spring

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

Methodology Applied
Scientific EffectImpact force reduction through geometric offset: Impact Force

Data Source

PatentEP3750731B1Charging socket
Publication Date: 2023.07.05 JUNGHEINRICH AG
  • EP3750731B1 patent drawingFigure 1
  • EP3750731B1 patent drawingFigure 2a
  • EP3750731B1 patent drawingFigure 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.