Charging Plug-in Connector Actuator Relocation
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Solution Overview
Problem
Existing charging plug-in connectors for electric vehicles are not user-friendly due to difficult access to the actuating mechanism, leading to potential damage and failure during handling and rapid charging procedures, which require high currents and robustness.
Innovation Solution
A charging plug-in connector design with a housing featuring a through-going grip opening and an actuator that extends into the grip opening, allowing secure handling with four fingers and protecting the actuator when dropped, along with a disconnector mechanism that ensures safe current flow only when correctly inserted, using an operating lever, lever arm, and latching arm to manage connection and disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the actuating means is arranged on the housing upper face, then the charging plug-in connector can be latched to a charging socket, but the actuating means is difficult to reach and may be damaged when the connector falls down
Solution Approach 1:
The actuator is moved from the upper face to the rear side of the housing, changing its spatial position to a different dimension. This allows the actuator to be accessible from the rear while the upper face remains free from sensitive components, resolving the contradiction between protection and accessibility.
2Ease of operation
If the actuator is placed on the upper face for easy access, then user-friendliness is improved, but the actuator is vulnerable to damage during handling and falls
Solution Approach 1:
The actuator is extracted from the upper face area and relocated to the rear side of the housing. This separation removes the vulnerable actuator from the zone prone to impact damage while maintaining operational accessibility through the through-going grip opening.
3Productivity
If the charging plug-in connector is designed for rapid charging with high currents, then charging speed is improved, but heat development and robustness requirements increase
Solution Approach 1:
The housing acts as an intermediary thermal management structure, providing thermal pathways and protection for the contact elements during high-current rapid charging operations.
Data Source
AI summary
A charging plug-in connector is provided that comprises a housing having a through-going grip opening and an actuator for activating a charging procedure, wherein the actuator extends at least in part into the through-going grip opening. This construction renders the charging plug-in connector particularly user-friendly and is still robust. If the charging plug-in connector falls down, the sensitive actuator is protected.