Modular Charging Inlet Assembly for Faster Terminal Service
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Solution Overview
Problem
Servicing of conventional charging inlet assemblies for vehicles is difficult due to the time-consuming process of disassembling and removing terminals from the housing, making maintenance and repairs cumbersome.
Innovation Solution
A modular design for charging inlet assemblies with removable AC and DC charging modules, each with a terminal holder, allowing for easy detachment and reassembly, and incorporating position assurance devices to ensure proper loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If terminals are individually removed from the housing using latches, then the charging inlet assembly can be serviced, but the servicing process becomes time-consuming and difficult
Solution Approach 1:
The charging inlet assembly is divided into modular terminal assemblies (AC terminal assembly and DC terminal assembly), each containing multiple terminals that are pre-assembled together. This segmentation allows the entire terminal assembly to be removed and replaced as a single unit rather than individually removing each terminal, significantly reducing servicing time while maintaining repairability.
2Ease of repair
If the charging inlet assembly is disassembled for service, then terminals can be replaced, but the entire assembly must be removed from the vehicle
Solution Approach 1:
The charging inlet assembly is segmented into the housing and removable terminal assemblies. Each terminal assembly (AC and DC) is a self-contained module that can be independently removed from the housing by disconnecting cable harnesses and releasing retaining clips, allowing terminal replacement without removing the entire charging inlet assembly from the vehicle.
Solution Approach 2:
The terminal assemblies are extracted as separate removable modules from the housing. Each terminal assembly includes the terminals, terminal holder, and associated cable harnesses, which can be detached and replaced independently, simplifying the repair process and reducing the scope of disassembly required.
Data Source
AI summary
A charging inlet assembly includes a housing extending between a front and a rear having a DC section configured for mating with a DC charging connector and an AC section configured for mating with an AC charging connector. The charging inlet assembly includes an AC charging module coupled to the rear of the housing at the AC section having an AC terminal holder holding AC terminals. The AC charging module is removable from the housing wherein the AC terminals are removed from the housing with the AC terminal holder. A DC charging module is coupled to the rear of the housing at the DC section having a DC terminal holder holding DC terminals. The DC charging module is removable from the housing wherein the DC terminals are removed from the housing with the DC terminal holder.