Locking Electrical Connector for Arc-Safe EV Battery Swapping
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Solution Overview
Problem
The challenge in electromobility is the short range of electric vehicles and long charging times, requiring quick and safe battery replacement to avoid damage from arcing and voltage peaks during connector disconnection, while existing plug-in systems are complex and costly.
Innovation Solution
A compact electrical plug connector with a locking bracket and latching mechanism, featuring a controllable locking device that uses an electromechanical actuator for secure and easy connection/disconnection, preventing arcing and ensuring safe operation under load, and incorporating a sealing element for protection against liquids and chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking bracket with latching mechanism is used to secure the connector, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The locking element is integrated directly into the coupling housing, merging the locking function with the housing structure. This eliminates the need for a separate locking bracket while maintaining reliable electrical and mechanical connection through the combined housing-locking element assembly.
Solution Approach 2:
The locking function is extracted from a separate locking bracket and incorporated as an integrated locking element within the coupling housing. This simplifies the overall device structure by removing the redundant locking bracket component while preserving the latching mechanism's reliability.
2Device complexity
If a locking element is integrated into the coupling housing to simplify the device, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The locking element is merged with the coupling housing as an integrated component, reducing the number of separate parts. This integration simplifies the device structure while the manufacturing precision is managed through the unified production process of the housing assembly.
Solution Approach 2:
The coupling housing serves multiple functions: it provides structural support, electrical connection, and integrated locking mechanism. This multi-functionality reduces the need for separate components and simplifies the overall device while the precision requirements are distributed across the housing's various functional features.
3Ease of operation
If the locking bracket is made movable from open to closed position for easy operation, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The locking element is designed with movable capability, allowing it to transition between locked and unlocked positions. This dynamic feature enables easy operation for battery replacement while the movement is achieved through the inherent flexibility and geometry of the integrated locking element within the housing.
Data Source
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AI summary
An electrical connector, in particular for signal and/or power transmission, preferably for charging electric vehicles or the batteries of electric vehicles, with a coupling housing for connection to a corresponding second electrical connector, wherein a locking lever is movably arranged on the coupling housing from an open position to a closed position, wherein the locking lever has a recess into which a locking element of the second connector can be inserted in the open position of the locking lever, and wherein in the closed position of the locking lever the locking element is arranged in the recess such that the coupling housing is positively and/or frictionally connected to the second connector, wherein a locking device with at least one locking element is arranged on the coupling housing.wherein the locking element engages in a locking receptacle of the locking bar in the closed position of the locking bar and wherein an electrically movable locking element is arranged which inhibits movement of the locking element in a locking position.