EV Connector With Electro-Mechanical Locking For Multi-Voltage Charging
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Solution Overview
Problem
Current electric vehicle charging standards, such as the SAE J1772 standard, limit charging efficiency, with Level 1 taking 24-26 hours, Level 2 taking 3-6 hours, and Level 3 taking 2-3 hours, and do not accommodate various international voltage standards, posing challenges for interoperability and user convenience.
Innovation Solution
An EV connector designed to comply with SAE J1772 standards for Level 1, 2, and 3 charging, with an electro-mechanical locking mechanism and adaptable to international standards, featuring a power cable that can connect to 440V, 220V, and 110V circuits, and an electro-mechanical manipulator for easy coupling and decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If Level 1 charging (110V, 15A) is used, then the vehicle can be charged using standard residential circuits with wide availability, but the charging time is excessively long (24-26 hours)
Solution Approach 1:
The charging system dynamically adapts between different charging levels (1, 2, and 3) based on circuit capability and user needs. The connector and control system can switch between standard 110V Level 1 charging and higher-power Level 2/3 charging configurations, allowing the system to optimize charging speed while maintaining compatibility with various circuit types.
2Loss of time
If Level 3 charging (440V) is used, then the charging time is reduced to 2-3 hours, but the infrastructure requirement becomes more complex and less widely available
Solution Approach 1:
The charging connector and system are designed with multi-functionality to support Level 1 (110V), Level 2 (220V), and Level 3 (440V) charging configurations through a single unified interface. The electro-mechanical locking mechanism and terminal configuration can adapt to different voltage levels and circuit types, providing universal compatibility across the full range of charging standards without requiring separate infrastructure for each level.
3Adaptability or versatility
If different international voltage standards are accommodated, then interoperability is improved, but the device complexity increases
Solution Approach 1:
The connector incorporates a universal design that can accommodate multiple international voltage standards (110V, 220V, 440V) and different plug configurations within a single device. The electro-mechanical locking mechanism and terminal arrangement are designed to work across various standards including SAE J1772, European, and Japanese specifications, eliminating the need for multiple specialized connectors.
Solution Approach 2:
The system allows dynamic adjustment of electrical parameters (voltage, current, terminal configuration) to match different international standards. The connector can change its operational parameters based on the detected standard or user selection, enabling interoperability without requiring physical hardware changes for each standard.
4Reliability
If an electro-mechanical locking mechanism is added, then connection reliability is improved, but the device complexity increases
Solution Approach 1:
The electro-mechanical locking mechanism operates automatically through self-service principles. The connector self-locks upon insertion and self-unlocks when decoupling is initiated, reducing the need for manual intervention. The locking mechanism integrates with the terminal connection process, so that connection and locking occur simultaneously without adding separate manual steps.
Data Source
AI summary
An electric vehicle, EV, connector configured for charging an electric vehicle, EV, charging receptacle, said plug connector comprising:a body havinga first plug end configured to be coupled to an EV charging receptacle on an electric vehicle for charging or recharging;a second power cable end configured to be coupled to a power cable, wherein the first end includes a terminal interface having one or more terminal receptacles for receiving one or more terminals positioned within the EV charging receptacle,and wherein the first end also includes a latching member positioned generally above the terminal interface, and is hingedly coupled to a part of the body to allow the latching member to move along a vertical access for coupling or decoupling the EV connector to the EV charging receptacle, and wherein the latching member is controlled by an electro mechanical manipulator provided inside the body, and arranged to control and allow the latching member to move along the vertical access.