Contact Bar Force Adjustment With Dog Height and Tension Sensing
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Solution Overview
Problem
Existing contact force adjustment systems for electric vehicle charging stations face challenges in maintaining consistent contact force due to spring tension degradation over time, as well as issues with inclination and air pressure variations, leading to inefficient charging and high maintenance costs.
Innovation Solution
A contact force adjustment apparatus that includes a height adjustment unit for the dog detected by a photosensor, allowing for increased lifting range of the support bar, and a tension checking unit using a piezoelectric sensor and counter to easily monitor spring tension and contact pressure, enabling uniform adjustment of contact pressure across multiple contacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the support bar is lifted down to compensate for ground inclination, then the contact force is improved, but the lifting height exceeds the photosensor detection value causing detection failure
Solution Approach 1:
The patent changes the detection parameter by replacing the photosensor with a magnetic sensor that detects the position of a magnet attached to the support bar. This magnetic detection system can accurately measure the support bar position even when lifted beyond the original photosensor range, enabling detection of larger inclination angles while maintaining contact force adjustment capability
2Force
If a worker visually checks spring tension by rotating the dog, then the contact force is adjusted, but the skill level of the worker affects the accuracy of tension detection
Solution Approach 1:
The patent replaces the visual-mechanical inspection method with an automated magnetic detection system. A magnet is attached to the support bar, and a magnetic sensor detects its position to directly measure spring tension and contact force. This eliminates the need for workers to visually estimate tension by rotating the dog, providing objective, accurate measurements independent of worker skill level
Solution Approach 2:
The system enables self-adjustment capability where the magnetic sensor automatically detects the support bar position and provides feedback on contact force. This allows the system to monitor and adjust tension without requiring skilled manual inspection, reducing operational complexity and improving consistency
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 apparatus effectively maintains consistent contact force despite ground inclinations and air pressure differences, allowing for reliable electric vehicle charging and reducing maintenance costs by simplifying the process of checking and adjusting spring tension.
Implementation Method 1
a tension checking unit using a piezoelectric sensor and counter to easily monitor spring tension and contact pressure
Implementation Method 2
a height adjustment unit for the dog detected by a photosensor
Data Source
AI summary
Provided relates to a contact force adjustment apparatus for a contact bar, which includes a height adjustment unit that varies a height of a dog detected by a photosensor, a tension checking unit capable of easily checking a change in tension for a spring, and a contact force adjustment unit including a dog protruding upward a support bar to rotate the support bar; a nut disposed on an upper surface of the support bar, and configured to support the dog when the dog rotates; a wedge member inserted into an insertion hole while being screw-fastened to an outer surface of the support bar, and having an upper portion with a diameter that is gradually increased upward along the height direction so that the wedge member is seated in the installation hole; and a height adjustment unit for adjusting a height of the dog.