Modular EV Charging Rail Mounting for Flexible Post Placement
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Solution Overview
Problem
Existing multi-outlet charge stations for electric vehicles face challenges in accurate post placement due to obstacles like rocks or stones, leading to time-consuming and labor-intensive installation, high costs, and difficulty in adapting to different layouts.
Innovation Solution
A modular charging arrangement with elongated rails and connection elements that allow for flexible mounting on posts or walls, enabling easy assembly and expansion by allowing rail connectors to be secured at a connection distance with a large tolerance, and featuring sliding and locking mechanisms for efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If posts are accurately located for multi-outlet charge stations, then the overground elements will fit properly, but the installation becomes time-consuming and labor-intensive
Solution Approach 1:
The charging station structure is divided into modular components (charging outlets, overground elements, support structures) that can be independently positioned and connected. This segmentation allows each module to be installed separately without requiring precise pre-positioning of all components, thereby improving installation speed while maintaining overall structural accuracy.
Solution Approach 2:
The patent introduces adjustable mounting brackets and positioning mechanisms as intermediary elements between the posts and overground elements. These intermediaries provide tolerance adjustment capabilities, allowing proper fitting without requiring extremely precise post placement, thus resolving the contradiction between accuracy requirements and installation efficiency.
2Manufacturing precision
If posts are placed in exact locations, then the charging station layout is optimized, but obstacles like rocks or stones make post placement difficult or impossible
Solution Approach 1:
The mounting system incorporates adjustable and movable components that can be positioned at various locations along the post structure. This dynamic positioning capability allows the charging outlets to be relocated if initial post placement is obstructed by terrain features, maintaining layout optimization while adapting to physical obstacles.
Solution Approach 2:
The patent employs adjustable mounting mechanisms that can modify positioning parameters (height, horizontal position, angle) of the overground elements relative to the posts. This parameter adjustability enables the system to compensate for post placement deviations caused by obstacles, preserving the intended charging station layout while accommodating terrain variations.
3Reliability
If traditional multi-outlet charge stations are installed, then charging functionality is provided, but the installation costs and labor requirements are high
Solution Approach 1:
The charging station is designed as an assembly of standardized modular units that can be manufactured separately and assembled on-site. This segmentation reduces manufacturing complexity and enables parallel installation of multiple modules, lowering both material costs and labor requirements while ensuring reliable charging functionality through proven modular designs.
Solution Approach 2:
The overground elements and support structures are designed to serve multiple functions: structural support, cable protection, and mounting for charging outlets. This multi-functionality reduces the total number of components needed, simplifying both manufacturing and installation processes while maintaining full charging capabilities, thereby reducing overall installation costs and labor.
Data Source
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AI summary
A modular charging arrangement (100) for charging a vehicle is provided. The modular charging arrangement (100) comprises a first and a second elongated rail (110a, 110b) having first and second rail connectors (111, 112) facing in a common direction, a mounting bracket (120) configured to be attached to an object, such as a post (200) or a wall, the mounting bracket (120) comprising a mounting surface (122) configured to secure the first rail connector (111) and the second rail connector (112) at a connection distance (D) from each other such that the first rail connector (111) and the second rail connector (112) faces away from the mounting surface (122) in a common connection direction (CCD), and a connection element (130) comprising a power outlet (133) and a first and a second connection element connector (131, 132) arranged at the connection distance (D) from each other such that the first connection element connector (131) engages the first rail connector (111) of the first elongated rail (110a) and the second connection element connector (132) engages the second rail connector (112) of the second elongated rail (110b) when the connection element (130) is translated towards the mounting surface (122) of the mounting bracket (120) in a direction opposite to the common connection direction (CCD). A method (700) of mounting a modular charging arrangement (100) for charging a vehicle is also provided.