Plug Connector Compensation Device for EV Charging Misalignment
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Solution Overview
Problem
Fully automatic or semi-automatic charging devices for electric vehicles face challenges in precisely detecting the position and axis alignment of plug connector parts, leading to potential tilting and strain on electrical contacts due to positional and angular deviations during charging, especially with vehicle movements.
Innovation Solution
A plug connector part with a compensation device comprising a housing, a carrier element, and a spring element that allows for resilient deformation to compensate for positional and angular deviations, ensuring secure engagement with a mating plug connector part by moving the carrier element relative to the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic plugging is used to enable fully automatic or semi-automatic charging devices, then productivity is improved, but measurement precision deteriorates because position detection with optical sensor systems is only possible with limited precision and axis detection is difficult
Solution Approach 1:
The patent changes the physical state of the contact elements by making them resilient (spring-loaded) instead of rigid. This allows the contact elements to deform elastically and compensate for positional and angular deviations during plugging, enabling automatic charging with limited detection precision while maintaining reliable electrical contact.
2Strength
If rigid connection is used to securely engage plug connector parts, then strength is improved, but adaptability deteriorates because positional and angular deviations cause tilting and strains on electrical contacts
Solution Approach 1:
The patent transforms the rigid static connection into a dynamic resilient connection. The contact elements are designed to move and deform elastically in response to positional and angular deviations, allowing the connector to adapt to misalignment while maintaining secure engagement and preventing damage to electrical contacts.
Solution Approach 2:
The resilient contact elements act as pre-designed cushioning elements that absorb and compensate for expected positional and angular deviations before they can cause damage. The spring-loaded design anticipates potential misalignment and provides mechanical compliance to prevent tilting and strains on the electrical contacts.
3Adaptability or versatility
If floating arrangement of contact carrier is used to compensate deviations, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent uses resilient contact elements that function as flexible mechanical components to compensate for deviations. Instead of a complex floating carrier arrangement, the invention employs spring-loaded contact elements that provide the necessary compliance through elastic deformation, achieving deviation compensation with a simpler structure.
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 compensation device effectively reduces tilting and strain on electrical contacts by accommodating deviations, ensuring reliable and secure electrical contact even with changes in vehicle position, thereby enhancing the stability and efficiency of charging processes.
Implementation Method 1
a spring element which biases the carrier element with respect to the housing, in such a way that the carrier element is movable relative to the housing by way of resilient deformation of the spring element
Data Source
AI summary
A plug connector part includes a plug housing that has at least one plug-in portion that can be connected to a mating plug connector part by plugging in an insertion direction so as to contact the plug connector part electrically with the mating plug connector part; and a compensation device arranged on the plug housing, the compensation device including: a housing; a carrier element connected to the plug housing and arranged on the housing; and a spring element that biases the carrier element with respect to the housing, wherein the carrier element is movable relative to the housing by way of resilient deformation of the spring element.