EV Plug Connector Gear Locking Mechanism
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Solution Overview
Problem
Existing electrical plug connections for electric vehicles face challenges in secure charging due to the complexity of assembly and potential malfunctions, particularly with separate components like holders and transmission elements, which can lead to unauthorized access and incomplete charging.
Innovation Solution
A compact electrical plug connection design utilizing a deflection gear to convert linear actuator movements into perpendicular adjustments, eliminating the need for flexible cables and allowing for a compact, cost-effective structure with automatic locking and sealing, featuring a gear arrangement and toothed rack sections for efficient locking and unlocking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components (holder, transmission element, blocking element) are used for the locking mechanism, then the locking function can be achieved, but the assembly complexity increases and potential malfunctions occur
Solution Approach 1:
The patent integrates the holder, transmission element, and blocking element into a single integrated component. The blocking element is directly formed as part of the holder structure, eliminating the need for separate assembly of multiple components. This merging approach maintains the locking function while significantly reducing assembly complexity and potential failure points from multiple connection interfaces.
Solution Approach 2:
The integrated holder is designed with distinct functional zones: a holding section for the cable connector, a transmission section with the transmission element, and a blocking section with the blocking element. This segmentation within a unified structure allows each function to be clearly defined while avoiding the complexity of separate components.
2Ease of operation
If an actuating cable is used as the transmission element, then the locking function can be transmitted, but the assembly and production complexity increases
Solution Approach 1:
The patent extracts the cable transmission element from the system and replaces it with a rigid lever arm integrated into the holder. This eliminates the need for flexible cables, bending radii considerations, and complex cable routing, significantly simplifying both manufacturing and assembly while maintaining the actuation function.
Solution Approach 2:
The flexible cable-based mechanical transmission is replaced with a rigid lever-based mechanical system. The lever arm provides direct mechanical coupling between the actuator and the blocking element, eliminating the intermediate cable and its associated assembly complexities.
3Device complexity
If a compact structure is achieved by eliminating flexible cables, then the design is simplified, but the transmission of actuating movements must be done at right angles
Solution Approach 1:
The patent solves the right-angle transmission requirement by using a lever arm that rotates about an axis perpendicular to both the actuator stroke direction and the blocking element movement direction. This three-dimensional arrangement allows compact right-angle force transmission without requiring complex mechanisms or flexible cables.
Solution Approach 2:
The lever arm is pre-positioned and pre-oriented during manufacturing to achieve the required right-angle configuration. This preliminary setup eliminates the need for complex assembly adjustments and ensures proper force transmission geometry from the start.
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 increased functional reliability and ease of assembly, ensuring secure charging by converting linear actuator movements into effective locking and unlocking actions without bending radii restrictions, enhancing safety and efficiency in electric vehicle charging.
Implementation Method 1
the gear arrangement comprises a worm wheel, a drive gear and a sector gear, and the locking element is a Pivoted lever which can be pivoted about a pivot axis. The worm gear meshes with the worm and is concentrically attached to the drive gear. The sector gear meshes with the drive gear and is fixed to the pivot lever.
Implementation Method 2
the actuator is a motor on whose output shaft a worm sits, the gear arrangement comprises a worm wheel
Implementation Method 3
A deflection gear is used, with the help of which adjustment movements of the actuator are converted into corresponding adjustment movements of the blocking element in a different direction.
Implementation Method 4
Both the drive pin and the locking pin or the actuating element 4 are each equipped with an associated toothed rack section 8a or 4a. The gear 5 meshes with both rack sections 4a, 8a.
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present invention relates to an electric plug-in connection, in particular for electric vehicles. Said plug-in connection is equipped with a plug-in connector (1, 2) substantially consisting of a socket (1) and a plug (2). The connection is also provided with a locking unit (4, 5) comprising at least one blocking element (4) and a transmission element (5) for detachably coupling the socket (1) and the plug (2). Further, an actuator (8) is provided, for actuating the transmission element (5) together with the blocking element (4) arranged at one end thereof. According to the invention, the transmission element (5) is in the form of a gear arrangement (5).