Detachable Charger Connector Alignment in Tight EVSE Space
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Solution Overview
Problem
Conventional charger systems face challenges in establishing a secure electrical connection to the grid due to limited space caused by larger cables and equipment, leading to potential issues like poor connections, arcing, and equipment damage.
Innovation Solution
A charger system comprising a stationary base and a detachable charger top with guided connectors that align and mate securely, using mechanical counterparts and moveable contactors to establish reliable connections, even in constrained spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional nut and bolt connection is used to establish electrical connection, then the connection can be established, but the space required for connection becomes excessively large due to thicker cables
Solution Approach 1:
The connector is divided into two separate parts: a base connector integrated into the base and a top connector integrated into the charger top. These segmented connectors mate together through guided alignment, enabling reliable electrical connection without requiring large connection space. The segmentation allows each connector to be optimized for its specific function while reducing overall space requirements.
Solution Approach 2:
Guide structures (guides) are introduced as intermediary elements between the base connector and top connector. These guides facilitate precise alignment and mating of the connectors, ensuring reliable electrical connection while minimizing the space required for the connection process. The guides act as mediators that enable accurate positioning without requiring excessive clearance.
2Power
If larger equipment and thicker cables are used for high power charging, then the power capacity is improved, but the overall dimension of the EVSE increases
Solution Approach 1:
The connector components are nested within the base and charger top structures respectively. The base connector is integrated into the base housing, and the top connector is integrated into the charger top housing. This nesting arrangement allows high power capability components to be contained within compact boundaries, maintaining small overall EVSE dimensions while supporting high charging power.
Solution Approach 2:
The connection system utilizes vertical stacking and layered arrangement of components. The base connector and top connector are positioned at different vertical levels and mate through vertical movement guided by the guide structures. This dimensional arrangement allows efficient space utilization, enabling high power components to be arranged compactly in three-dimensional space rather than requiring large horizontal footprint.
3Ease of operation
If manual alignment of connectors is attempted in limited space, then connection can be established, but the installation process becomes complex and error-prone
Solution Approach 1:
The guide structures enable the connectors to self-align and self-mate during the assembly process. When the charger top is installed, the guides automatically guide the top connector into proper alignment with the base connector without requiring manual intervention for positioning. This self-aligning mechanism simplifies installation while maintaining connection reliability, reducing both operational complexity and potential for errors.
Data Source
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AI summary
A charger system (1, 2, 3, 4) and a corresponding assembling method are provided. The charger system (1, 2, 3, 4) includes a stationary base (20) including a base connector (30, 130, 131, 132) electrically connectible to an electrical supply line (22) and a base guide (21), and the charger system (1, 2, 3, 4) further includes a detachable charger top (50) including a charger device (80), a top connector (60, 160, 161, 162) electrically connected to the charger device (80), and a top guide (51). When the charger top (50) is mounted to the base (20), the top guide (51) is configured to mate with the base guide (21) such as to bring the top connector (60, 161, 162, 163) and the base connector (30, 130, 131, 132) into a predetermined positional relation to each other.