Movable Contact Elements in EV Charging Connectors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric vehicle charging devices lack effective protection against accidental contact with direct current (DC) contact elements, and the integration of contactors to address this issue complicates the design and increases costs.
Innovation Solution
A charging device with mechanically movable contact elements that retract into the connector when unoccupied, eliminating the need for contactors and reducing friction during connection, while ensuring protection against touch through controlled movement by a control device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactors are integrated into the charging device to protect against accidental contact with DC contact elements, then protection against touch is improved, but device complexity and costs increase
Solution Approach 1:
The contact elements are designed to be movable rather than fixed, allowing them to dynamically change position between a retracted first position (when no connector is connected) and an extended second position (when connectors are connected). This dynamic mechanism provides protection against accidental touch without requiring additional contactor devices, thereby resolving the contradiction between safety and device complexity.
2Device complexity
If contact elements are kept stationary to simplify the design, then device complexity is reduced, but protection against accidental contact is compromised
Solution Approach 1:
The contact elements transition from a static design to a dynamic one with controlled movement capability. The movement is actuated by the control device based on connector connection status, providing the necessary protection while maintaining design simplicity by using the existing connector detection mechanism rather than adding separate contactor control systems.
3Reliability
If contact elements are retracted into the charging connector to protect against touch, then protection against accidental contact is improved, but friction during connection increases
Solution Approach 1:
The connector connection process is divided into sequential stages: first the mechanical connection of the charging connectors is established, then the control device actuates the contact elements to move from the retracted first position to the extended second position. This preliminary action of establishing mechanical connection before extending contact elements minimizes friction and insertion forces while ensuring protection against accidental touch during the connection process.
Data Source
AI summary
A charging device for an electric vehicle has a first charging connector on the vehicle side for mechanically connecting to a second charging connector of an external charging station. The first charging connector has two contact elements for a DC charging process. A galvanic connection of the contact elements to an electric energy store is provided, wherein direct current flows into the electric energy store. A control device monitors the charging process and is capable of communicating with the charging station. The charging device has at least one contact element movable between a first and a second position. In the first position, the contact element is retracted in the first charging connector, and in the second position the contact element is arranged so as to contact a corresponding contact of the second charging connector when the first and the second charging connectors are mechanically connected.