EV Charging Connector Locking Mechanism
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Solution Overview
Problem
Existing electrical connectors for electric vehicle charging lack a unified, reliable, and compact mechanism for vandal resistance, plug locking during use, and easy insertion, while ensuring safety and compliance with EN 62196 standards.
Innovation Solution
An electrical connector with a casing and female contacts protected by shutters, featuring a slider-activated rocking arm mechanism that locks the plug in place and prevents extraction, combined with a locking frame and compression springs for secure shutters operation, and a lip-shaped gasket for IP sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate mechanisms are used for vandal resistance and plug locking, then each function can be independently optimized, but the device complexity increases
Solution Approach 1:
The patent combines the vandal-resistant shutter mechanism and the plug locking mechanism into a single integrated locking mechanism. The rocker arm serves dual functions: it controls the shutters to prevent access to female contacts when closed, and simultaneously locks the plug in the inserted position. This merging eliminates the need for separate mechanisms while maintaining both vandal resistance and plug security functions.
Solution Approach 2:
The locking mechanism is designed as a universal component that performs multiple functions. The rocker arm can switch between controlling the shutters and locking the plug, depending on the operational state. This multi-functionality reduces the overall number of components and simplifies the device structure while ensuring both protection modes are adequately addressed.
2Reliability
If a robust locking mechanism is implemented, then plug security is improved, but the ease of insertion deteriorates
Solution Approach 1:
The locking mechanism employs a rocker arm that can dynamically switch between different operational states. During insertion, the rocker arm is in a first position where it does not obstruct the plug. Once the plug is inserted, the rocker arm transitions to a second position where it engages with the plug to prevent extraction. This dynamic behavior allows the mechanism to provide strong locking when needed while remaining unobtrusive during insertion.
Solution Approach 2:
The mechanism is designed so that the locking action occurs automatically as a result of the insertion process itself. The plug insertion triggers the rocker arm to transition to the locked position, eliminating the need for separate locking operations. This preliminary action ensures that the locking function is integrated into the natural insertion sequence, maintaining ease of operation.
3Reliability
If shutters are used to protect female contacts, then safety is improved, but the device complexity increases
Solution Approach 1:
The shutter control function is merged with the plug locking function within the same rocker arm mechanism. The rocker arm's movement simultaneously controls both the shutters and the plug lock, eliminating the need for a separate shutter actuation mechanism. This integration reduces device complexity while maintaining contact protection through the shutters.
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
The solution provides a single, efficient mechanism for vandal resistance, easy plug insertion, and reliable locking, ensuring EN 62196 compliance and IP55 sealing, enhancing safety and usability in various charging facilities.
Implementation Method 1
compression springs for secure shutters operation
Implementation Method 2
a slider-activated rocking arm mechanism that locks the plug in place
Data Source
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AI summary
An electrical connector including a casing provided with a front opening and adapted to receive at the rear a female contacts body in which a plug inserted in the front opening can engage; the female contacts are protected by a pair of shutters, which prevent access to the female contacts when the shutters are in the closed position; the connector is characterized in that it includes a single locking mechanism which controls the opening of the shutters and the locking of the plug when it is inserted in the female contacts body.