EV Charging Connector Linkage Alignment Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electric vehicle charging systems are slow due to the limitations of traditional connectors, which cannot handle high voltage and current requirements, making it cumbersome and time-consuming to charge vehicles, especially those in constant use like emergency and public transportation vehicles.
Innovation Solution
A connector arrangement with a linkage mechanism and sensors that automatically align and engage connectors for faster charging, allowing for higher power delivery up to 500 Amp at 1,600 Volt by maintaining safe air distance and using a compact design for easier manual operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional connectors are used for charging, then the connector structure is simple and easy to manufacture, but the charging speed is slow and charging time is long
Solution Approach 1:
The connector is divided into multiple components including a body, cap, and internal electrical contacts. The body is segmented into regions for different electrical connections, allowing high-voltage and low-voltage contacts to be spatially separated while maintaining a compact overall structure that enables faster charging.
Solution Approach 2:
The connector design transitions from a simple plug interface to a multi-dimensional structure with vertical stacking of electrical contacts and three-dimensional arrangement of conductive elements. This allows multiple electrical connections to be made simultaneously through a single connector interface, enabling high-power fast charging without proportionally increasing connector size.
2Loss of time
If higher power delivery is implemented (500 Amp at 1,600 Volt), then charging time is reduced, but the connector size and manual operation difficulty increase
Solution Approach 1:
The connector design nests multiple electrical contacts and conductive elements within a compact body structure. The cap contains internal features that guide alignment, and the overall assembly fits within a space-efficient form factor. This nesting allows high-power delivery capabilities to be achieved without requiring a proportionally larger connector that would be difficult to handle manually.
Solution Approach 2:
The cap serves as an intermediary component between the connector body and the vehicle interface. It provides mechanical guidance, electrical insulation, and alignment features that facilitate easy manual connection while enabling the underlying high-power electrical contacts to function at 500 Amp and 1,600 Volt without requiring the user to directly manipulate the high-voltage elements.
3Reliability
If connector alignment precision is improved, then engagement reliability is increased, but the alignment mechanism complexity increases
Solution Approach 1:
The connector body and cap feature asymmetric geometries with unique shaping on mating surfaces. The cap has an asymmetric profile that complements the body's shape, creating a single correct orientation for engagement. This asymmetric design provides self-alignment and prevents misconnection without requiring complex active alignment mechanisms, sensors, or actuators.
Solution Approach 2:
The connector design incorporates preliminary alignment features such as guide pins, tapered surfaces, and pre-positioned electrical contacts that automatically align the body and cap during the approach phase of connection. These features perform the alignment action before final engagement, ensuring reliable contact establishment without requiring complex real-time adjustment mechanisms during the connection process.
Data Source
AI summary
A connector arrangement for charging an electric vehicle includes a first connector disposed adjacent a slide surface and having a pin extending from the first connector. A second connector has a second connector body and is moveable along the slide surface by a linkage mechanism. A socket extends through the second connector body between two opposed openings, and at least one sensor is associated with the second connector body. The at least one sensor provides information indicative of a location of the second connector body on the slide surface to the linkage mechanism.