Half Fitting Prevention Connector for Electric Vehicles
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Solution Overview
Problem
Existing power supply connectors for electric vehicles often experience arc discharges due to incomplete fitting, caused by interference friction between connector housings, leading to a half-engaged state where charging current can flow, resulting in terminal disconnection and potential damage.
Innovation Solution
A half-fitting prevention connector design featuring a cylindrical case with a rotatable lever, release lever, and an electromagnetic coil that prevents charging by ensuring the connector is fully fitted before allowing current flow, using a microswitch activated by the electromagnetic coil only when the connector is completely engaged, thereby preventing arc discharges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector uses a lever mechanism for low insertion force fitting, then the ease of operation is improved, but the reliability deteriorates due to half-engaging state caused by interference friction
Solution Approach 1:
The patent applies preliminary anti-action by using an electromagnetic coil to generate a holding force that prevents the lever from returning to its original position when interference friction causes incomplete engagement. The electromagnetic force counteracts the tendency of the lever to disengage, maintaining terminal connection even when the fitting is not complete, thus preventing arc discharge while preserving the ease of operation provided by the lever mechanism.
Solution Approach 2:
The electromagnetic coil acts as an intermediary between the mechanical lever mechanism and the electrical connection stability. It mediates the transition from mechanical engagement to electrical connection by providing electromagnetic holding force that ensures terminal connection is maintained, bridging the gap caused by interference friction in the mechanical fitting process.
2Productivity
If the connector allows charging current flow upon signal terminal connection, then the productivity is improved, but the object-affected harmful factors worsen due to arc discharge in half-fitted state
Solution Approach 1:
The patent applies preliminary action by using the electromagnetic coil to establish terminal connection and prevent lever return before charging current is allowed to flow. The signal terminal connection triggers the electromagnetic holding force to be activated, which preliminarily ensures proper engagement and prevents half-fitted state, thereby allowing charging to proceed safely without arc discharge damage.
Solution Approach 2:
The system uses feedback from signal terminal connection to control the electromagnetic coil activation. When signal terminals are connected, this triggers the electromagnetic holding force to engage, which then prevents lever return and ensures stable terminal connection before charging current flows. This feedback mechanism ensures that charging only proceeds when proper engagement is detected, preventing arc discharge while maintaining high productivity.
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 arc discharges by ensuring the connector is fully fitted before initiating charging, maintaining terminal connection and preventing damage from shock-induced disconnections, while also offering flexibility in electromagnetic coil layout and malfunction prevention.
Implementation Method 1
An electromagnetic coil 13 having a plunger 13P is provided on the cylindrical case 10C. The electromagnetic coil 13 is excited by connection between the signal terminal 10T2 of the connector body 10M and the signal terminal 20T2 of the mating connector 200, and thereby moving the plunger 13P toward the microswitch 14.
Data Source
Figure 1A~1C
Figure 2
Figure 3A~3B
AI summary
A half fitting prevention connector includes a cylindrical case, a connector body, a lever, and a release lever. The release lever has a lock hole. An electromagnetic coil has a plunger. The plunger is arranged so as to face a microswitch. The electromagnetic coil is excited by connection between the signal terminal of the connector body and a signal terminal of a mating connector, and thereby moving the plunger toward the microswitch. The release lever is rotatable so that the plunger can enter the lock hole to press the microswitch in a state that the connector body is completely fitted with the mating connector and the plunger cannot enter the lock hole in a state that the connector body is half fitted with the mating connector.