EV Battery Connector Alignment and Shielding
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Solution Overview
Problem
Current electric vehicles with removable battery packs face challenges in efficiently exchanging batteries due to misalignment issues and electromagnetic interference between high voltage power connections and data connections, leading to increased complexity and cost.
Innovation Solution
A system and method for quickly exchanging battery packs in electric vehicles, utilizing a network of charge spots and battery exchange stations, with a battery bay design that includes a frame with latch mechanisms and a transmission assembly for simultaneous rotation of latches, and a shielding mechanism to mitigate electromagnetic interference, allowing for both power and data connections to be made in a single electrical connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If high voltage power connections and data connections are placed in close proximity in the electrical connection system, then the system complexity is reduced, but electromagnetic interference occurs between the connections
Solution Approach 1:
A shielding mechanism is introduced as an intermediary element between the high voltage power connections and data connections. This shield acts as a mediator that blocks electromagnetic fields from the power connections from interfering with the data connections, allowing both types of connections to coexist in close proximity without direct electromagnetic interference.
Solution Approach 2:
The electrical connection system employs different structural characteristics in different local regions. Specifically, shielding is applied only in areas where power connections and data connections are in close proximity, while other areas maintain their original connection structures. This localized application of shielding reduces overall system complexity while addressing electromagnetic interference where it occurs.
2Productivity
If the battery exchange process is accelerated to reduce recharging time, then productivity is improved, but misalignment between battery and vehicle connectors increases
Solution Approach 1:
Alignment features such as guide pins and alignment slots are pre-configured in both the battery pack and vehicle connector before the exchange process begins. These preliminary alignment structures ensure that even during rapid exchange operations, the connectors automatically align correctly without requiring precise manual positioning or complex alignment mechanisms.
Solution Approach 2:
The connector design incorporates adjustable parameters such as spring-loaded contact elements and flexible connection components that can adapt to minor misalignments. These parameter changes allow the connection system to maintain reliable electrical contact even when perfect alignment is not achieved during rapid battery exchange.
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
Enables rapid battery exchange in less than one minute, reducing the need for lengthy recharging, lowering vehicle costs by separating battery ownership from the vehicle, and maintaining efficient data and power connectivity despite misalignment and electromagnetic interference.
Implementation Method 1
a shielding mechanism to mitigate electromagnetic interference
Data Source
AI summary
The connection system is designed to facilitate electrical and data connections between the battery and the electric vehicle. The connectors are designed with alignment mechanisms to account for initial misalignment of the battery and vehicle while still ensuring positive contact between them. The alignment mechanisms also introduce compliance into the system to ensure that the mechanical components of the system are not placed under unwanted loads or stresses. The connection system houses data connectors carrying communication signals as well as power connectors carrying high voltage electricity. The data connectors are shielded to prevent interference caused by proximity to the high voltage elements. The connection system uses no mechanical latching or locking mechanisms.