Automated EV Battery Connector Attachment Mechanism
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Solution Overview
Problem
The existing battery replacement type electric vehicles require manual connection and disconnection of high-voltage connectors, increasing replacement time, cost, and safety risks.
Innovation Solution
A device with a connector housing, a connecting member, a movable member, an elastic member, and a power transmitting member that automatically connects and disconnects high-voltage connectors between the battery and the vehicle using a pinion gear and rack gears, facilitated by guide members and a guide pin, allowing for efficient and safe battery replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual connection and disconnection of high-voltage connectors is used, then device complexity is reduced, but productivity decreases and safety risks increase
Solution Approach 1:
The connector attachment device is nested within the battery mounting module structure. The connector housing is integrated into the mounting module, and the connecting member is housed within the connector housing, creating a compact nested arrangement that automates connector attachment without requiring separate external equipment.
Solution Approach 2:
The device enables self-service automation where the battery replacement process automatically performs connector attachment and disconnection through the integrated mechanism. The movable member and power transmitting member work together to automatically connect/disconnect high-voltage connectors during battery replacement without manual intervention.
2Loss of time
If manual connection of high-voltage connectors is performed, then ease of operation is maintained, but time consumption increases
Solution Approach 1:
The battery replacement operation and connector attachment operation are merged into a single integrated process. As the battery is inserted into or removed from the mounting module, the movable member automatically moves to connect or disconnect the high-voltage connectors, combining two separate operations into one simultaneous action.
Solution Approach 2:
The connector attachment device is pre-positioned and pre-configured within the battery mounting module before battery replacement occurs. The connecting member is预先 positioned within the connector housing, and the power transmitting member is pre-aligned, enabling immediate automatic connection as soon as the battery is inserted without requiring additional setup steps.
3Reliability
If manual connector connection is used, then device complexity remains low, but safety reliability decreases
Solution Approach 1:
The connector housing serves as an intermediary structure between the battery connector and the vehicle's high-voltage system. The movable member acts as a mediator that automatically engages the battery connector with the vehicle connector through controlled movement, ensuring proper alignment and secure connection without direct manual handling of exposed electrical contacts.
Solution Approach 2:
The manual mechanical operation of connector attachment is replaced with an automated mechanical system driven by the power transmitting member. The rack gear and pinion gear mechanism automatically converts the linear movement of the movable member into the rotational motion needed to engage and secure the high-voltage connectors, eliminating manual manipulation.
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 device enables convenient and rapid battery replacement while reducing safety risks by automating the connection and disconnection of high-voltage connectors, thus enhancing operational efficiency and safety.
Implementation Method 1
an elastic member connected with the movable member and the connector housing to apply an elastic force to the movable member
Implementation Method 2
a power transmitting member connected to the connecting member and the movable member and that moves the connecting member opposite to the movement direction of the movable member
Data Source
AI summary
A device is provided that attaches and dettaches a connector for an electric vehicle of a battery replacement type. The device automatically connects and separates a connector at a battery and a connector at a vehicle when replacing a battery in an electric vehicle. The device may include a connector housing that is disposed on a battery mounting module for mounting and separating the battery and a connecting member that is connected to a cable at the vehicle, movably disposed within the connector housing, and selectively connected with the connector at the battery. A movable member is movably disposed within the connector housing in correspondence to the connecting member by a guide pin of the connector at the battery and a power transmitting member is connected to the connecting member and the movable member and moves the connecting member opposite to the movement direction of the movable member.