EV Connector Unit With Switched High-Voltage Charging Path
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Solution Overview
Problem
Current plug-in electrical vehicles require multiple high-voltage electrical connections, increasing manufacturing costs and complexity, and posing reliability and safety risks due to the complexity of the high-voltage energy storage system.
Innovation Solution
A connector unit with a single high-voltage electrical connection that temporarily disconnects the high-voltage energy storage from the propulsion motor during charging, using a switching mechanism to route charging current directly to the energy storage while preventing exposure to the electrical motor, thereby reducing the number of high-voltage connections and enhancing safety and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple high-voltage electrical connections are used for the energy storage system, then the vehicle can operate in both driving and charging modes, but the manufacturing cost and system complexity increase
Solution Approach 1:
The patent combines the driving mode connection and charging mode connection into a single high-voltage electrical connection. The connector unit integrates multiple functions (driving connection, charging connection, and switching control) into one unified structure, eliminating the need for separate connections for different operational modes.
Solution Approach 2:
The patent employs a switching mechanism that dynamically reconfigures the single high-voltage connection between different modes. The controller activates or deactivates the connection based on operational requirements, allowing the same physical connection to serve multiple functions at different times.
2Adaptability or versatility
If multiple high-voltage electrical connections are used, then the system can support both driving and charging operations, but reliability and safety are compromised due to increased complexity
Solution Approach 1:
By merging multiple connections into one, the patent reduces the number of potential failure points. A single connector unit with integrated switching control is more reliable than multiple separate connections, as it eliminates interface complexity and potential connection errors between multiple components.
Solution Approach 2:
The switching mechanism acts as an intermediary between the single high-voltage connection and the energy storage system. It provides safe isolation and controlled connection/disconnection, preventing direct exposure to high voltage during charging operations and enhancing overall system safety.
3Device complexity
If a single high-voltage electrical connection is used, then manufacturing cost and complexity are reduced, but the ability to distinguish between driving and charging modes must be managed through switching mechanisms
Solution Approach 1:
The switching mechanism is automatically controlled by a controller that detects the operational mode and activates or deactivates the connection accordingly. The system serves itself by autonomously managing the switching based on charging or driving conditions, eliminating the need for manual intervention.
Solution Approach 2:
The patent replaces manual mechanical switching with an electronically controlled switching mechanism. The controller uses electrical signals to activate or deactivate the high-voltage connection, substituting complex manual operational procedures with automated electronic control.
Data Source
AI summary
A connector unit for a plug-in electrical vehicle includes a first set of terminals for connection with a high-voltage energy storage, a second set of terminals for connection with an electrical propulsion motor, a connector interface having electrical connectors and being configured for temporarily receiving a corresponding connector interface of a charging connector during charging of the high-voltage energy storage of the plug-in electrical vehicle, and a permanent or temporary electrical connection between the first set of terminals and the second set of terminals.