EV Charging Connector Latch Sensing for Stable Socket Coupling
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Solution Overview
Problem
Existing charging connectors for electric vehicles lack a reliable mechanism to ensure a mechanically stable connection, which can be compromised by environmental factors due to lightweight designs.
Innovation Solution
The charging connector incorporates a sensor to indicate a safe fastening, featuring a first external casing and a second inner casing that encloses the charging connector interface and cable, with the sensor arranged outside the inner casing to detect correct mechanical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a lightweight casing is used to reduce connector weight, then the weight is reduced, but the susceptibility to environmental conditions increases
Solution Approach 1:
The connector casing is divided into two separate casings: a first lightweight external casing and a second protective inner casing. This segmentation allows the external casing to be optimized for weight reduction while the inner casing provides environmental protection, resolving the contradiction between weight reduction and environmental susceptibility.
Solution Approach 2:
The second inner casing is nested within the first external casing, creating a protective enclosure for the sensor and internal components. This nested structure enables the outer casing to remain lightweight while the inner casing shields against environmental factors, simultaneously achieving weight reduction and environmental protection.
2Reliability
If a sensor is added to detect safe fastening, then the connection stability is improved, but the device complexity increases
Solution Approach 1:
The sensor is integrated into the existing connector structure and positioned within the inner casing, merging the detection function with the protective enclosure. This integration minimizes additional complexity by utilizing the existing casing structure rather than adding separate mounting components.
Solution Approach 2:
The sensor automatically detects the latch position and connection status without requiring external intervention or complex processing systems. The sensor provides self-monitoring capability that enhances reliability while maintaining simplicity through autonomous operation.
Data Source
AI summary
A charging connector for a vehicle charging station comprises a latch configured to secure a mechanical connection of the charging connector to a vehicle-side socket, the charging connector further comprising a sensor configured to indicate a secure and correct mechanical connection. The charging connector further comprises a first casing being an external casing, and a second casing, the second casing being a closed inner casing. The second casing encloses a charging connector interface to the vehicle socket, and a charging cable. The sensor is arranged outside the second casing.