Modular EV Cable Assembly with Lockable Connectors
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Solution Overview
Problem
Standard electric vehicle supply equipment often relies on fixed cable assemblies, limiting flexibility in voltage and charge rate selection, and may not adapt to different regional power outlet requirements, leading to inefficiencies and potential damage from improper usage.
Innovation Solution
An interchangeable electrical cable assembly with lockable connectors and an adapter receptacle system that allows for multiple voltage and charge rate configurations, including a controller to determine input AC voltage and control output AC, enabling compatibility with various outlets and regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed cable assembly is used, then the device structure is simple, but the adaptability to different voltage and outlet types is poor
Solution Approach 1:
The cable assembly is divided into separate modular components including interchangeable plugs for different outlet types (NEMA 5-15, NEMA 6-15, NEMA 14-50, etc.), a common adapter receptacle, and a vehicle connector assembly. This segmentation allows users to swap plugs based on available outlets while maintaining a unified base structure, thereby improving adaptability without requiring complete cable replacement.
Solution Approach 2:
The adapter receptacle is designed as a universal interface that can accept multiple types of electrical plugs. The common housing and cable structure serve multiple functions by supporting different plug configurations, enabling a single cable assembly to work with various outlet types and voltage configurations (120V, 240V, single-phase, three-phase).
2Adaptability or versatility
If a fixed cable assembly is used, then the manufacturing process is simple, but the flexibility in voltage and charge rate selection is limited
Solution Approach 1:
The cable assembly incorporates dynamic configurability through interchangeable plugs that can be swapped based on the available power outlet and desired charge rate. The system transitions from a static, fixed configuration to a dynamic, user-adjustable configuration, allowing flexibility in voltage selection (120V/240V) and charge rates without requiring complex manufacturing processes.
Solution Approach 2:
Multiple plug types are pre-configured and available for attachment to the adapter receptacle. Users can select and attach the appropriate plug before connecting to the outlet, ensuring compatibility and optimal charge rate selection in advance. This preliminary configuration approach simplifies the manufacturing process while providing flexibility.
3Reliability
If proper voltage matching is not implemented, then the device is simpler, but the risk of cord damage and improper usage increases
Solution Approach 1:
The controller incorporates voltage detection capability that monitors the input voltage from the electrical outlet. Based on the detected voltage level, the controller automatically adjusts the charging parameters and output characteristics to match the appropriate charge rate. This feedback mechanism prevents improper voltage application that could damage the cable or vehicle battery, while maintaining relatively simple device architecture through intelligent control.
Data Source
AI summary
An electrical cable assembly is provided with an electrical connector sized to be received into an electrical outlet. A cable is in electrical communication with the electrical connector. A lockable connector is in electrical communication with the cable. An adapter receptacle is sized to receive the lockable connector for electrical communication with the lockable connector. The lockable connector is lockable within the adapter receptacle. A vehicle connector assembly is in electrical communication with the adapter receptacle and is sized to be received by a vehicle receptacle to convey current to the vehicle receptacle.