Overload Coupler Drive Element for EV Charging Connectors
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Solution Overview
Problem
The service life of drive elements in electrical connectors, particularly in charging connectors for electric vehicles, does not meet high requirements due to failure from acceleration and braking forces, often resulting in broken teeth.
Innovation Solution
A drive element with a continuously extending recess in the circumferential direction forms a friction-based overload coupler between the gear wheel and hub, allowing for axial form-fitting and circumferential frictional locking, which mitigates the effects of acceleration and braking forces by acting as a torque limiter, preventing failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional drive element with discrete projections and recesses is used, then the structure is simple and easy to manufacture, but the service life is insufficient due to failure from acceleration and braking forces
Solution Approach 1:
The overload coupler is designed to slip before the gear teeth fail, preventing the harmful effect of tooth breakage. The friction-based connection with continuously extending recess prepares the system to absorb overload forces before they can cause catastrophic failure.
Solution Approach 2:
The friction-based overload coupler converts the harmful acceleration and braking forces into beneficial frictional engagement between the hub part and gear-wheel part. The continuously extending recess allows controlled slippage that protects the gear teeth from breaking while maintaining drive functionality.
2Reliability
If an overload coupler with discrete segments is used, then the manufacturing is simpler, but the torque transmission is interrupted and reliability is reduced
Solution Approach 1:
The continuously extending recess is extracted from the gear-wheel part, creating a dedicated friction surface that runs continuously in the circumferential direction. This allows the overload coupler to function as a separate protective element while maintaining simple manufacturing through injection molding or similar processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly extends the service life of the drive element and electrical connector by preventing failures due to overload, maintaining functionality even when torque limits are exceeded.
Implementation Method 1
the hub part is held in a frictionally locking manner in the gear-wheel part in a circumferential direction, thereby forming a friction-based overload coupler between the gear wheel and the hub part
Implementation Method 2
the effects of acceleration and braking on the service life of the drive element appear to be mitigated. In particular, a failure of the drive element or of the entire electrical connector owing to a broken tooth can be prevented successfully by way of the inventive measures
Data Source
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AI summary
The invention relates to an electrical connector (1) with a driven element (4) and a drive (2) driving the driven element, and a drive element (8) between the drive and the driven element and also a drive element for such an electrical connector. The electrical connector can be, for example, a charging connector for an electric vehicle. In such a case, the driven element is a locking bolt, which is moved by an electric motor as a drive. The drive element (8) is part of a gear unit (10) and has a gear wheel (16). In order to increase the service life of the electrical connector (1), according to the invention an overload coupler (14) is integrated in the drive element between the gearwheel and a hub (30) of the drive element.