EV Charging Connector Latching Mechanism for Autonomous High-Power Connection
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Solution Overview
Problem
High-power electric vehicle charging requires high insertion forces due to heavy connectors and high currents, posing challenges for autonomous connection and safety, especially with aging connectors and varying manufacturing tolerances.
Innovation Solution
A latching mechanism using a puller arm with a gripping element that aligns with an inlet, applies compressive force, and remains extended to connect electrodes, capturing the gripping element in a state to prevent disconnection, facilitating autonomous and safe high-power charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high insertion forces are applied to connect the connector to the inlet, then reliable electrical connection is achieved, but autonomous operation becomes difficult and safety risks increase
Solution Approach 1:
The connector performs self-alignment and self-latching through its own structural features. The colinear axes guide automatic alignment, while the puller arm and gripping element automatically engage with the inlet to secure the connection without external assistance, enabling autonomous operation despite high insertion forces
Solution Approach 2:
The puller arm acts as an intermediary mechanism between the connector body and the inlet. It extends to apply controlled compressive force through the gripping element, mediating the high insertion force requirement while enabling autonomous connection through a dedicated latching structure
2Power
If the connector structure is made robust to handle high currents, then power transfer capability is improved, but the insertion force requirement increases
Solution Approach 1:
The connector structure is segmented into functional components: the main connector body for power transfer, the puller arm for force application, and the gripping element for latching. This segmentation allows the robust connector body to handle high currents while the specialized puller arm mechanism manages the high insertion forces separately
3Reliability
If manufacturing tolerances are tightened to ensure proper alignment, then connection reliability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The colinear axes are designed to establish preliminary alignment between the connector and inlet before the actual connection is made. This pre-alignment mechanism compensates for manufacturing tolerances by guiding the components into proper position automatically, reducing the need for tight manufacturing precision
Solution Approach 2:
The asymmetric positioning of the colinear axes and the puller arm creates a unique alignment path that guides the connector into the correct position. This asymmetric design ensures proper alignment even with varying manufacturing tolerances, as the geometry itself enforces the correct relative positioning
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 reliable and autonomous connection of high-power chargers to electric vehicles, overcoming high insertion forces and ensuring safety by maintaining contact despite manufacturing variations and environmental factors.
Implementation Method 1
the puller arm comprises a gripping element configured to apply a first compressive force against the inlet
Data Source
AI summary
A method for latching an electrical connector includes aligning a connector with an inlet. A first surface of the connector is within a first distance of a second surface of the inlet. A puller arm of the connector is extended into the inlet to a second distance from the second surface of the inlet. The puller arm includes a gripping element configured to apply a first compressive force against the inlet. The puller arm is retracted relative to the connector while applying the first compressive force against the inlet. The puller arm remains in the inlet at the second distance, thereby inserting a first electrode of the connector into the inlet to connect the first electrode with a second electrode of the inlet. The first electrode transfers power to the second electrode from a high-power supply.