Detachable EV Charging Cable Interface to Cut Weight and Cable Count
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Solution Overview
Problem
The increasing weight and purchase cost of vehicles due to the mounting and use of in-cable control boxes, portable cables, and charging cables for electric vehicles and plug-in hybrid vehicles.
Innovation Solution
A charging control box detachable charging cable system that uses a detachable common cable with physical and electrical devices to confirm the fastened state, preventing erroneous connections and reducing the need for multiple cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple charging cables (portable cable and charging cable) are mounted in the vehicle, then charging functionality is ensured, but vehicle weight increases and power consumption increases
Solution Approach 1:
The vehicle cable is designed to serve multiple charging functions by itself. It can connect to both the charging control box (for slow charging) and external power sources (for portable charging), replacing the need for separate portable cable and charging cable. This multi-functional design reduces vehicle weight while maintaining all charging capabilities.
2Adaptability or versatility
If multiple charging cables are mounted in the vehicle, then all charging systems can be used, but purchase cost increases
Solution Approach 1:
The vehicle cable is designed with universal compatibility to work with both the charging control box and external power sources. By integrating both connection capabilities into a single cable, the system maintains adaptability to all charging methods while reducing the quantity of cables from two to one, thereby lowering purchase cost.
3Reliability
If in-cable control box is mounted, then charging control is improved, but device complexity and cost increase
Solution Approach 1:
The control box is extracted from the cable and mounted separately in the vehicle. This separation allows the cable to be simpler and more flexible, while the control functionality remains in the stationary control box. The vehicle cable becomes a pure connection component without integrated control electronics, reducing cable complexity while maintaining charging control capabilities.
Data Source
AI summary
A charging control box detachable charging cable system includes a vehicle cable having a vehicle terminal on one end for connection to a first connection terminal of a charging control box or an external power source, and an outlet on the other end for connection to a charging inlet of a vehicle. The system also includes a portable cable having one end for connection to the external power source, and a portable terminal provided on the other end for connection to a second connection terminal of the charging control box. The vehicle terminal has a first corresponding key configured to be engaged and coupled with the first key of the first connection terminal, and the portable terminal has a second corresponding key configured to be engaged and coupled with the second key of the second connection terminal.