PCB-Integrated Charging Post Controller for Wiring-Free Module Assembly
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Solution Overview
Problem
The existing charging post systems require manual cable wiring for electrical connections between various control modules and low-voltage components, leading to high hardware and human resource costs, long production cycles, and low production efficiency and reliability.
Innovation Solution
A charging post controller with various functional modules connected via a PCB, integrating the monitoring unit and direct-current main loop unit on a mounting and fixing unit, eliminating the need for manual wire distribution and reducing the complexity of the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cable wiring is used to connect control modules and low-voltage components, then electrical connections can be established, but the process becomes complicated leading to high hardware costs, high human resource costs, long production cycles, and low production efficiency
Solution Approach 1:
The patent integrates multiple control modules (monitoring unit, direct-current main circuit unit, and other functional modules) onto a single PCB board. This merging of previously separate components into one integrated circuit board eliminates the need for manual cable wiring between modules, directly resolving the contradiction by reducing connection complexity while maintaining reliable electrical connections.
2Ease of manufacture
If control modules and low-voltage components are provided separately with independent shells and wiring ports, then each module can be independently manufactured, but they occupy great space and require great workloads in processing and assembling
Solution Approach 1:
The patent combines multiple separately manufactured control modules into a single integrated PCB assembly. The monitoring unit, direct-current main circuit unit, and other functional modules are merged onto one board, dramatically reducing the total volume occupied in the charging post while maintaining the ease of manufacture through standardized PCB fabrication processes.
Solution Approach 2:
The patent transitions from a three-dimensional arrangement of separate boxed modules to a two-dimensional PCB layout. This dimensional change allows multiple functional modules to be densely packed on a flat circuit board, significantly reducing the space required while maintaining independent functionality of each module through dedicated circuit regions.
3Reliability
If manual cable wiring is used for electrical connections, then connections can be established, but the process is greatly affected by human factors leading to high human resource costs and long production cycles
Solution Approach 1:
The patent replaces the mechanical process of manual cable wiring with an automated PCB manufacturing process. Electrical connections are established through standardized PCB trace routing and soldering techniques during board fabrication, eliminating human factor variability and enabling high-volume automated production, thereby improving both connection reliability and production efficiency.
4Adaptability or versatility
If various control modules and low-voltage electrical components are purchased from different manufacturers and wired manually, then system functionality can be achieved, but hardware cost and human resource cost increase significantly
Solution Approach 1:
The patent consolidates multiple control modules from different manufacturers into a single integrated PCB design. By merging the monitoring unit, direct-current main circuit unit, and other functional modules onto one board, the system maintains full functionality while reducing the quantity of separate components, wiring materials, and assembly labor required, thereby significantly reducing both hardware and human resource costs.
Data Source
AI summary
A charging post controller with various functional modules connected by a PCB, and a charging post thereof. The controller includes a monitoring unit (1), a direct-current main loop unit (2) and a mounting and fixing unit (3), wherein the monitoring unit (1) comprises a PCB (11) and an electronic circuit forming electrically connected functional modules (4), and the functional modules (4) are mounted on the mounting and fixing unit (3), to form a laminated arrangement structure among the monitoring unit (1), the direct-current main loop unit (2) and the mounting and fixing unit (3). A charging post using the controller has a relatively high degree of integration, relatively small overall volume and relatively low comprehensive cost, and is relatively easily promoted and applied.