Docking Connector Assembly With Self-Alignment for EV Chargers
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Solution Overview
Problem
Conventional docking connector assemblies for electric vehicle chargers face challenges in achieving smooth electrical/physical coupling due to slight positional errors between devices, leading to a high risk of failure and fire.
Innovation Solution
A docking connector assembly with a first connector on a moving object and a second connector on a fixed or moving object, allowing for axial movement and rotational adjustment to correct positional errors, ensuring secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed connector design is used, then the structure is simple, but coupling fails when positional errors occur between devices
Solution Approach 1:
The connector incorporates a movable body that can dynamically adjust its position along the docking guide and rotate around the docking terminal axis. This dynamic capability allows the connector to compensate for positional errors and angular misalignments between mating connectors, thereby improving coupling reliability without requiring overly complex fixed structures
Solution Approach 2:
The connector is divided into distinct functional segments: a movable body for positional adjustment, a rotational mechanism for angular alignment, and a docking terminal for electrical connection. This segmentation allows each component to perform its specific function independently, resolving the contradiction between reliability and complexity by making the complexity manageable and functional
2Adaptability or versatility
If the connector allows movement and rotation, then positional errors are corrected, but the device complexity increases
Solution Approach 1:
The connector employs a movable body that can slide along the docking guide and a rotational mechanism that enables angular adjustment. These dynamic features provide adaptability to positional and angular errors while keeping the mechanism relatively simple through the use of guide rails and rotational joints rather than complex multi-axis positioning systems
Solution Approach 2:
The docking guide acts as an intermediary element that constrains and guides the movement of the movable body, ensuring that adjustments are made in a controlled manner. This intermediary structure simplifies the overall mechanism by providing natural guidance paths rather than requiring active control systems for each degree of freedom
3Ease of operation
If precise alignment is required, then coupling is secure, but the operation becomes difficult when positional errors exist
Solution Approach 1:
The movable body is designed to make preliminary contact with the docking guide before final coupling is achieved. This preliminary action allows the connector to self-align and compensate for positional errors automatically during the approach phase, making operation easier without requiring high manufacturing precision for the final coupling position
Solution Approach 2:
The connector system performs self-alignment through the interaction between the movable body and the docking guide. The guide structure automatically directs the movable body into the correct position and orientation, eliminating the need for external alignment tools or complex control systems, thereby improving ease of operation while maintaining secure coupling
Data Source
AI summary
Disclosed is a docking connector assembly according to various embodiments of the present invention, which is designed to solve the problem as described above. The docking connector assembly may comprise: a first connector which is provided in a charging cart; and a second connector which is provided to be couplable to the first connector, wherein the second connector is provided to be movable in one or more axial directions and rotatable about an arbitrary axis.