Modular Vehicle Charging Connector Assembly Design
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Solution Overview
Problem
Existing electrical connector assemblies for vehicle charging lack flexibility to accommodate various electrical harness configurations and current ratings, leading to inefficiencies and increased complexity in manufacturing and assembly.
Innovation Solution
A modular connector assembly design that includes interchangeable components such as blocker plates, retainer plates, and tubes, allowing for different electrical harness configurations and current ratings, with a latching mechanism for secure attachment and a molded material for insulation and strain relief, integrated with a cordset assembly for versatile and standardized vehicle charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed electrical connector design is used, then manufacturing is simpler, but adaptability to different electrical harness configurations is reduced
Solution Approach 1:
The connector assembly is divided into modular components including a connector body, interchangeable blocker plates, retainer plates, and tubes. Each component can be independently selected and assembled to match different electrical harness configurations, enabling versatility without requiring complete redesign of the entire connector assembly.
Solution Approach 2:
The connector body is designed as a universal platform that can accommodate multiple electrical harness configurations through interchangeable internal components. The standardized connector body interface allows the same base structure to serve multiple functions with different current ratings and harness arrangements by simply changing the blocker plate and retainer plate assembly.
2Adaptability or versatility
If interchangeable components are added for different configurations, then adaptability improves, but assembly complexity increases
Solution Approach 1:
The connector is segmented into standardized modules (connector body, blocker plates, retainer plates, tubes) that can be manufactured separately using optimized processes for each component type, then assembled through standardized interfaces that reduce overall assembly complexity despite the variety of configurations.
Solution Approach 2:
Different electrical harness configurations are achieved by changing specific parameters of the internal components (such as blocker plate aperture sizes and retainer plate dimensions) while maintaining the same overall connector body structure and assembly procedure, allowing versatility without proportionally increasing manufacturing complexity.
Data Source
AI summary
A connector assembly having a body is provided. The body forms an inlet, an internal cavity, and an outlet. A plate is oriented in the cavity and adjacent to the outlet. A harness partially extends through the inlet, into the cavity, and is connected to the plate. A molded material is disposed over the harness within the internal cavity on an inlet side of the plate. The molded material includes an integrally formed grommet that is oriented at the inlet of the body for providing strain relief to the harness.