Replaceable Pin for EV Charging Inlet Terminal
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Solution Overview
Problem
Electric vehicle charging terminals face durability issues due to harsh environments, leading to increased contact resistance, power loss, and the need for costly replacement of entire cable harnesses, which is time-consuming and requires professional service.
Innovation Solution
A replaceable pin system for charging inlet assemblies, where the pin is removably coupled to a head with a mating shaft, allowing for easy installation and removal without disassembling the housing, using a socket tool for threading and a spring for forward bias, enabling separate replacement of the mating interface without affecting the entire terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire cable harness is replaced when the terminal deteriorates, then reliability is improved, but loss of time and manufacturing cost increase significantly
Solution Approach 1:
The terminal is divided into two replaceable parts: a head portion that remains in the housing and a pin portion that can be independently replaced. This segmentation allows only the worn pin to be replaced rather than the entire terminal assembly, reducing replacement time and cost while maintaining reliability of the remaining head portion.
Solution Approach 2:
The pin is extracted as a separate removable component from the head assembly. The pin can be independently removed and replaced without affecting the head or requiring disassembly of the housing, enabling quick field replacement and reducing service time while restoring terminal reliability.
2Reliability
If the entire cable harness is replaced when the terminal deteriorates, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The terminal is segmented into a permanent head assembly and a replaceable pin component. This reduces the complexity of the overall system by allowing selective replacement of only the pin, rather than requiring replacement of the entire cable harness assembly.
Solution Approach 2:
The pin is designed as a lower-cost, replaceable component that can be independently replaced when worn. This eliminates the need to replace expensive cable harness assemblies, reducing overall device complexity and cost while maintaining terminal reliability.
3Reliability
If the terminal is made secure in the housing, then reliability is improved, but ease of repair worsens
Solution Approach 1:
The terminal is segmented into a head portion secured in the housing and a separate pin portion that can be independently accessed and replaced. This allows the head to remain securely mounted while the pin can be easily removed and replaced without requiring disassembly of the housing or removal of the head.
Solution Approach 2:
The pin is extracted as a separately accessible component that can be removed from the head assembly without affecting the head's secure mounting in the housing. This enables easy field replacement of the pin while maintaining the reliability and security of the overall terminal assembly.
4Adaptability or versatility
If the terminal is exposed to harsh environments, then charging function is maintained, but durability deteriorates
Solution Approach 1:
The pin, which is directly exposed to harsh charging environments and suffers from abrasion and corrosion, is extracted as a separate replaceable component. This allows the pin to be replaced when deteriorated from environmental exposure, while the head portion protected inside the housing can continue to function, extending the overall service life of the terminal assembly.
Solution Approach 2:
The pin is designed to be discarded when worn from environmental exposure and replaced with a new pin. This allows recovery and continued use of the more durable head portion that remains protected in the housing, extending the service life of the terminal system while maintaining charging functionality in harsh environments.
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
This solution extends the service life of the terminal by allowing for the replacement of only the worn or damaged mating interface, reducing costs and maintenance time, while maintaining electrical and thermal coupling, and preventing corrosion.
Implementation Method 1
The terminal includes a spring surrounding the mating shaft positioned between the rear of the replaceable pin and the flange at the front of the head. The spring engages the replaceable pin to forward bias the replaceable pin away from the head.
Implementation Method 2
The mating shaft is threadably coupled to at least one of the head or the replaceable pin in a corresponding threaded bore of the head or the replaceable pin.
Data Source
AI summary
A terminal for a charging inlet assembly includes a head, a mating shaft, and a replaceable pin removably coupled to the head. The head is secured in a terminal channel of a housing of the charging inlet assembly having a terminating end configured to be terminated to a power cable. The mating shaft has threads. The replaceable pin has an outer surface defining a separable mating interface for mating engagement with a charging conductor of a charging connector. The replaceable pin has a drive base at the rear including drive teeth configured to be engaged by a socket tool to rotate the replaceable pin relative to the head for installing or removing the replaceable pin. The mating shaft is threadably coupled to at least one of the head or the replaceable pin in a corresponding threaded bore of the head or the replaceable pin.