Guided Charger Connector Assembly for Compact EVSE Cable Connections
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Solution Overview
Problem
Conventional charger systems face challenges in establishing secure connections between larger cables and electrical supply lines due to limited space, leading to potential issues like poor connections, arcing, and equipment damage.
Innovation Solution
A charger system comprising a stationary base and a detachable charger top with guided connectors that align and mate mechanically, allowing for a reliable electrical connection through a method that includes installing the connector on the cable before lowering the charger top onto the base, using guides to ensure proper alignment and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional nut and bolt connection is used to connect thicker cables to the electrical supply line, then the connection security is improved, but the space required inside the EVSE increases
Solution Approach 1:
The connection system is segmented into a base connector fixed to the electrical supply line and a top connector attached to the cable. This segmentation allows the connection to be made in two stages: first securing the base connector to the supply line, then bringing the cable with its top connector into position. The guides ensure proper alignment during this process, enabling secure connection without requiring excessive internal space for maneuvering thick cables.
Solution Approach 2:
The base connector is pre-installed and fixed to the electrical supply line before the cable is connected. The guides are also pre-positioned to establish the correct alignment path. This preliminary action allows the cable to be brought into position and connected to the base connector without requiring complex routing space, as the connection point and alignment path are already established.
2Volume of moving object
If the overall dimension of the EVSE is reduced, then the compactness is improved, but the space for establishing cable connection becomes limited
Solution Approach 1:
The connection process utilizes the vertical dimension by having the base connector fixed at the bottom and the top connector lowered from above. The guides extend vertically to guide the top connector into proper alignment with the base connector. This vertical arrangement allows thick cables to be connected without requiring excessive horizontal space, enabling compact EVSE design while maintaining adequate connection space.
3Manufacturing precision
If guides are used to align connectors, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The guides act as intermediary elements between the base connector and the top connector. Rather than requiring complex alignment mechanisms or precise manual positioning, the guides provide a simple mechanical interface that automatically ensures proper alignment as the top connector is lowered onto the base connector. This intermediary structure simplifies the overall alignment process while maintaining high precision.
Data Source
AI summary
A charger system is disclosed. The charger system includes a stationary base including a base connector electrically connectible to an electrical supply line and a base guide. The charger system further includes a detachable charger top including a charger device, a top connector electrically connected to the charger device, and a top guide. When the charger top is mounted to the base, the top guide is configured to mate with the base guide such as to bring the top connector and the base connector into a predetermined positional relation to each other.