Multistage Transmission for EV Charging Locking Mechanism

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Solution Overview

Problem

Existing electric connection devices for electric or hybrid motor vehicles face challenges in absorbing large forces acting on the charging plug and locking element while maintaining a compact drive design, as previous solutions are kinematically unfavorable and unable to provide high output torque efficiently.

Innovation Solution

The electric connection device features a multistage transmission with parallel shafts and evoloid gearing, allowing for a compact design that accommodates high torques and reduces noise, with a three-stage layout and additional engagement means for emergency unlocking, including a cam and manually-actuatable crank.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a conventional electromechanical drive with a cam-based multistage transmission is used, then the locking element can be actuated, but high lateral forces act on the locking element and the design cannot provide high output torque efficiently

Engineering Contradiction:

Improveoutput torqueVSAvoidtransmission layout

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent transitions from a conventional planar cam-based transmission to a three-dimensional parallel shaft arrangement with evoloid gearing. This dimensional change allows the transmission of high torque through parallel axes rather than through lateral cam forces, resolving the contradiction between power transmission capability and device complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent replaces the cam-based mechanical transmission system with an evoloid gear transmission system. The evoloid gearing provides direct meshing between parallel shafts, eliminating the lateral force issues inherent in cam mechanisms while maintaining compact dimensions. This substitution enables efficient high torque transmission without increasing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Volume of moving object

If the drive is made more compact, then space is saved, but the ability to absorb large forces acting on the locking element is reduced

Engineering Contradiction:

Improvedrive sizeVSAvoidforce absorption capability

Core Design Contradiction:

Volume of moving objectVSForce

Solution Approach 1:

The patent employs composite structural design in the transmission system, combining parallel shaft arrangements with evoloid gear meshes. This composite mechanical structure achieves both compact volume and high force absorption capability by distributing loads across multiple gear contact points rather than concentrating forces in a single cam mechanism.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The evoloid gearing utilizes curved tooth profiles that engage smoothly between parallel shafts. This curvature design allows for gradual load transfer and reduces stress concentrations, enabling the compact drive to absorb large forces effectively while maintaining small dimensions.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Ease of operation

If a cam-based transmission is used, then the locking element can be actuated, but high lateral forces are generated that are kinematically unfavorable

Engineering Contradiction:

Improvelocking element actuationVSAvoidlateral forces on locking element

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The patent replaces the cam-based actuation mechanism with an evoloid gear-driven parallel shaft transmission. This substitution eliminates the lateral force generation inherent in cam profiles while maintaining smooth locking element actuation through the meshing action of the evoloid gears, which transmit force axially rather than laterally.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This configuration enables efficient absorption of large forces and provides high output torque while maintaining a compact design, enhancing the reliability and efficiency of the locking mechanism.

Implementation Method 1

The electric connection device features a multistage transmission with parallel shafts and evoloid gearing, allowing for a compact design that accommodates high torques and reduces noise

Methodology Applied

Scientific EffectEvoloid gearing: Gear

Implementation Method 2

The multistage transmission operates on the locking element by way of a cam

Methodology Applied

Scientific EffectCam: Cam

Data Source

PatentUS11325487B2Electric connection device for electric or hybrid motor vehicles

Publication Date: 2022.05.10 KIEKERT AG

AI summary

An electric connection device for electric or hybrid motor vehicles, said connection device being equipped with a charging plug socket, a charging plug, a movable locking element for releasably locking the charging plug in the charging plug socket, and a drive for moving the locking element, said drive having an electric motor and a multistage transmission for acting on the locking element. The multistage transmission has individual shafts, each of which is arranged parallel to the output shaft of the electric motor as part of the drive. The device may use gearing to actuate a sensor to determine how far one of the individual shafts has rotated. An emergency unlocking crank may be mounted to a separate shaft that is engageable with one of the individual shafts via a cam.