EV Charging Connector Separation for Precision Alignment and Insertion Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric vehicle charging systems face challenges in achieving high precision and high insertion force for automatic connection, making them complex and expensive to develop.
Innovation Solution
The system separates precision and force actuation methods by using a first mechanism for precise positioning of the plug head and a second mechanism for high force insertion, reducing complexity and cost by utilizing a plug head connector with complementary shapes and mechanisms for secure coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a single mechanism is used to achieve both high precision positioning and high force insertion, then the connection can be fully automated, but the device complexity and cost increase significantly
Solution Approach 1:
The connection system is divided into two separate mechanisms: a first mechanism (plug head coupler with shape complementary to plug head lock) responsible for high-precision positioning and locking, and a second mechanism (plug connector with electrical contacts) responsible for high-force insertion and electrical coupling. This segmentation allows each mechanism to be optimized for its specific function, reducing overall system complexity while maintaining full automation.
2Extent of automation
If a single mechanism is used to achieve both high precision positioning and high force insertion, then the connection can be fully automated, but the development cost increases significantly
Solution Approach 1:
By segmenting the connection system into two independent mechanisms with distinct functions (positioning/locking and insertion/electrical coupling), the patent reduces development and manufacturing costs. Each mechanism can be designed, tested, and manufactured separately using appropriate technologies and materials, avoiding the need to develop a single complex high-precision-high-force mechanism.
3Manufacturing precision
If high precision is used for positioning, then the plug head can be accurately aligned with the inlet, but the force production capability is insufficient for secure coupling
Solution Approach 1:
The patent assigns the high-precision positioning function to the first mechanism (plug head coupler and lock system) and the high-force insertion function to the second mechanism (plug connector with electrical contacts). This functional segmentation allows each mechanism to be optimized for its primary requirement without compromise.
Solution Approach 2:
While the mechanisms are functionally segmented, they are structurally merged into a single integrated plug head assembly that connects to the vehicle inlet. The first mechanism provides positioning and locking, while the second mechanism provides insertion force and electrical coupling, and both work together as a unified connection system.
4Force
If high force is used for insertion, then the plug head can be securely coupled, but the positioning precision is insufficient for accurate alignment
Solution Approach 1:
The patent divides the connection function into two separate mechanisms: one dedicated to high-precision positioning (first mechanism with plug head lock and complementary coupler) and another dedicated to high-force insertion (second mechanism with plug connector and electrical contacts). This prevents the force application from compromising positioning precision.
Data Source
AI summary
An electric charging system includes an automatic connection device (ACD) outside a chargeable device. The ACD is electrically coupled to an energy source and includes a plug head electrically and mechanically connectable to the chargeable device and a first mechanism that positions the plug head at an inlet. The head includes a plug head connector with electrically conductive pins and a plug head lock with a first shape. The inlet includes electrically conductive sockets complementary to the electrically conductive pins; a plug head coupler including a shape that is complementary to the first shape and mechanically couples with the plug head via the plug head lock; and a second mechanism that mechanically and electrically couples the pins to the sockets. The second mechanism can produce a force greater than the first mechanism, and the first mechanism moves with greater translational and rotational precision than the second mechanism.