Modular EV Charger Assemblies for Fast Field Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle charging systems require on-site servicing, which exposes technicians to harsh environmental conditions and results in prolonged downtime due to the integrated nature of components, making maintenance inefficient.
Innovation Solution
A modular and interchangeable design for vehicle charging systems, featuring removable modules with integrated display screens, user input interfaces, and electrical interfaces, allowing for easy decoupling and replacement as a single unit, along with holster assemblies and tray assemblies that facilitate easy installation and removal of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are integrated and hardwired together in the vehicle charging system, then system reliability is improved, but serviceability deteriorates requiring on-site troubleshooting and repair
Solution Approach 1:
The vehicle charging system is divided into modular assemblies (charging cable assembly, holster assembly, display assembly, payment module) that can be independently removed and replaced. This segmentation allows technicians to replace entire functional modules rather than troubleshooting individual hardwired components, significantly improving serviceability while maintaining system reliability through standardized connections.
2Productivity
If technicians perform on-site servicing in harsh environmental conditions, then system maintenance is achieved, but technician safety and comfort deteriorate
Solution Approach 1:
Modular assemblies are pre-assembled and tested in controlled manufacturing environments before deployment. This preliminary assembly allows quality control and functionality verification to be performed in comfortable conditions, reducing the need for complex on-site troubleshooting and minimizing technician exposure to harsh environmental conditions during maintenance.
3Ease of repair
If the vehicle charging system remains offline during servicing, then repair work can be performed, but system availability deteriorates requiring several trips by the technician
Solution Approach 1:
The charging cable assembly and other modular components are designed to be easily extracted from the system housing through quick-release mechanisms. This extraction allows technicians to replace faulty assemblies with pre-tested units in a single visit, eliminating the need to leave the system offline for extended periods or require multiple trips for diagnostics and repair.
4Strength
If multiple fasteners are used to secure the removable module, then mechanical strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
The removable module housing incorporates universal attachment features that can be secured with minimal fasteners while maintaining adequate mechanical strength. The design uses standardized mounting interfaces and distributed fastener placement that provides both structural integrity and ease of assembly/disassembly, reducing manufacturing complexity compared to custom high-strength fastening solutions.
Data Source
AI summary
A vehicle charging system includes one or more removable modules, one or more removable panels, and a holster configured to secure a charging coupler. A removable module includes, for example, a housing, a display screen attached to the housing, a user input interface attached to the housing, an electrical interface for coupling to the vehicle charging system, and control circuitry attached to the housing and coupled to the display screen, the user input interface, and the electrical interface. The removable holster includes a holster support, a holster skin to receive the charging cable coupler, and a retention feature configured to retain the charging cable coupler in the cavity of the holster skin. The vehicle charging system includes one or more trays, each having a slot for mounting and positioning the assembly inside a vehicle charging system. A busbar and at least one electrical component may be attached to the tray.