Finger Protective Cap Interference Fit for EV Charging Terminal
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Solution Overview
Problem
The existing charging terminals in new energy vehicles experience stress concentration and fracture due to high-frequency vibration during ultrasonic welding, and the finger protective caps are easily detached, posing a risk of electric shock.
Innovation Solution
A finger protective cap design with an insertion post and radial protrusion that interference fits with the installation part of the connection terminal, reducing stress concentration and preventing detachment, while an arc-shaped connection part and reduced mass of the installation part mitigate vibration-induced fractures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the installation part is designed as a solid body with smaller diameter than the columnar body part, then the finger protective cap can be installed on the connection terminal, but stress concentration occurs at the root of the installation part leading to fatigue and fracture during ultrasonic welding
Solution Approach 1:
The root of the installation part is designed with an arc-shaped connection part that curves smoothly to connect with the columnar body part. This curved transition eliminates sharp corners and stress concentration points, allowing the installation part to withstand high-frequency vibrations during ultrasonic welding without fracturing.
2Strength
If the installation part is designed as a solid body, then it provides structural integrity, but the mass is relatively large causing high-frequency vibration and fatigue during ultrasonic welding
Solution Approach 1:
The installation part is segmented by introducing a hollow cavity inside it, while maintaining the outer structural integrity. This hollow structure significantly reduces the mass of the installation part, thereby reducing high-frequency vibrations and fatigue during ultrasonic welding, while the arc-shaped connection part ensures structural strength is maintained.
3Ease of operation
If the finger protective cap is installed on the end of the connection terminal, then it provides protection, but it is easily detached during the mating process between charging terminals
Solution Approach 1:
The finger protective cap is designed with an elastic material that provides dynamic adaptation. The elastic property allows the cap to deform slightly during the mating process and then return to its original shape, maintaining continuous contact and secure attachment with the installation part, preventing detachment while providing protection.
4Adaptability or versatility
If the installation part has a smaller diameter than the columnar body part, then it allows for the installation of finger protective cap, but creates stress concentration at the root connection
Solution Approach 1:
The root of the installation part is designed with an arc-shaped connection part that curves smoothly to connect with the columnar body part. This curved transition eliminates sharp corners and stress concentration points, allowing the installation part to withstand high-frequency vibrations during ultrasonic welding without fracturing.
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 effectively prevents fractures during high-frequency vibrations and ensures the finger protective cap remains securely attached, enhancing safety by preventing electric shock.
Implementation Method 1
The insertion post is insertable into an insertion hole on the installation part and interference fit with a hole wall of the insertion hole
Implementation Method 2
an arc-shaped connection part and reduced mass of the installation part mitigate vibration-induced fractures
Data Source
AI summary
A finger protective cap for fitting on an installation part at an end of a connection terminal includes a peripheral wall, an end wall connected to an end of the peripheral wall, and an insertion post located in the inner cavity and connected to the end wall. The peripheral wall and end wall define an inner cavity accommodating the installation part. The insertion post is insertable into an insertion hole on the installation part and interference fit with a hole wall of the insertion hole. The inner cavity has an opening opposite to the end wall to allow the installation part to be inserted into the finger protective cap through the opening.