EV Charging Connector with Split Precision and Insertion Mechanics
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges in achieving precise alignment and high insertion force for automatic connection, leading to complexity and cost due to the need for a single mechanical actuation system to manage both high precision and high force requirements.
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 through distinct mechanisms for each stage of the connection process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a single mechanical actuation system is used to manage both high precision positioning and high force insertion, then the system can perform automatic connection, but the system complexity and cost increase
Solution Approach 1:
The patent divides the mechanical actuation system into two separate mechanisms: a first mechanism dedicated to high precision positioning of the plug head, and a second mechanism dedicated to high force insertion. This segmentation allows each mechanism to be optimized for its specific function, reducing overall system complexity while maintaining automatic connection capability
Solution Approach 2:
The patent extracts the precision positioning function from the force insertion function by using a locking mechanism that secures the plug head in position before the actual insertion occurs. This separation removes the requirement for a single complex mechanism to handle both functions simultaneously
2Extent of automation
If a single mechanical actuation system is used to manage both high precision positioning and high force insertion, then the system can perform automatic connection, but the cost increases
Solution Approach 1:
By segmenting the actuation system into separate precision positioning and force insertion mechanisms, each component can be manufactured using simpler, more cost-effective methods appropriate to its specific function, rather than requiring a single high-performance mechanism that would be expensive to manufacture
3Force
If high insertion force is applied during positioning, then secure coupling is achieved, but positioning precision is compromised
Solution Approach 1:
The patent applies preliminary action by using the first mechanism to position the plug head with high precision before the second mechanism applies high insertion force. The locking mechanism secures the plug head in the correct position prior to forceful insertion, ensuring that the high force does not compromise positioning precision
Solution Approach 2:
The separation of positioning and insertion functions into distinct mechanisms allows high force to be applied independently after positioning is complete, eliminating the trade-off between force and precision that would exist in a single integrated system
4Manufacturing precision
If high positioning precision is maintained throughout insertion, then alignment is accurate, but the force required increases system complexity
Solution Approach 1:
The patent segments the mechanical system so that only the first mechanism requires high positioning precision, while the second mechanism for force insertion has relaxed precision requirements. This segmentation reduces overall system complexity compared to maintaining high precision throughout the entire insertion process
Solution Approach 2:
High positioning precision is applied preliminarily during the positioning phase, after which the locking mechanism maintains this position during the subsequent force insertion phase. This allows precision to be concentrated where needed rather than maintained throughout the entire process
Data Source
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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.