Magnetic EV Charging Interconnector for Heavy Cable Alignment
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges in forming stable and reliable connections due to the weight and complexity of high-power charging cables, necessitating improved methods for assisting users or automated systems in connecting charging connectors to vehicle inlets.
Innovation Solution
The integration of magnetic elements, including permanent and electromagnets, in connectors and vehicle inlets to create an attractive magnetic interaction that assists in aligning and inserting the connector into the inlet, reducing mechanical stress and ensuring a secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-power charging cables are used to provide up to 3000 Amperes charging current, then charging power is improved, but cable weight and complexity increase
Solution Approach 1:
The patent replaces the mechanical connection system with a magnetic field-based connection system. Electromagnets in the connector and corresponding magnetic elements in the inlet interact through magnetic attraction to form the electrical connection, eliminating the need for heavy mechanical cable structures while maintaining high power transmission capability up to 3000 Amperes.
Solution Approach 2:
The patent changes the fundamental parameter of connection formation from mechanical force to magnetic field interaction. By using controllable electromagnetic fields instead of physical cable mass, the system achieves high power transmission with reduced weight and complexity while maintaining connection stability.
2Power
If high-power charging cables are used to provide up to 3000 Amperes charging current, then charging power is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical cable assemblies with a simplified electromagnetic field-based connection system. The connector contains electromagnets that interact with magnetic elements in the inlet, eliminating the need for complex mechanical coupling mechanisms while supporting high power transmission.
Solution Approach 2:
The electromagnetic connection system serves multiple functions simultaneously: it provides electrical connection, ensures proper alignment through magnetic attraction, and enables controlled connection and disconnection. This multi-functionality reduces overall system complexity compared to separate mechanical and electrical connection systems.
3Reliability
If user manually connects heavy charging cable, then charging connection is formed, but ease of operation deteriorates
Solution Approach 1:
The patent replaces manual mechanical connection operations with automated magnetic field-based connection. The electromagnets automatically attract and align the connector with the inlet, forming a reliable electrical connection without requiring user effort to handle heavy cables or perform precise alignment.
Solution Approach 2:
The magnetic connection system performs self-alignment and self-connection through electromagnetic attraction between the connector and inlet. The system automatically forms the electrical connection without requiring user intervention for positioning or securing, while maintaining connection reliability.
4Ease of operation
If magnetic elements are integrated in connector and inlet, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent merges the magnetic field generation capability directly into the connector structure through integrated electromagnets. This combining of connection and alignment functions into a single integrated system reduces overall complexity compared to having separate mechanical and magnetic components.
Solution Approach 2:
The electromagnets in the connector serve multiple purposes: generating magnetic attraction for connection, providing alignment guidance, and enabling controlled disconnection. This multi-functionality reduces the need for additional separate components, thereby managing complexity while improving ease of operation.
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 magnetic interaction facilitates easier, safer, and more reliable charging connections by reducing the force required for insertion and alignment, thereby increasing the lifespan of charging components and minimizing downtime.
Implementation Method 1
The first magnetic element comprises an electromagnet
Implementation Method 2
The magnetic interaction between the first magnetic element and the second magnetic element is attractive so that a magnetic interaction force attracts the interconnector to the complement
Data Source
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Figure 5
AI summary
An interconnector for forming an electrical connection between a direct current, DC, charging station and an electric vehicle is described. The interconnector includes at least one first magnetic element configured for interacting, by magnetic interaction, with a second magnetic element of a complement for the interconnector. The first magnetic element includes an electromagnet. The magnetic interaction between the first magnetic element and the second magnetic element is attractive so that a magnetic interaction force attracts the interconnector to the complement.