Rotatable EV Charging Plug Assembly for Low-Twist Insertion
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Solution Overview
Problem
The rigid and torsionally stiff charging cables for electric vehicles require significant user effort to twist and insert into the vehicle, especially at low temperatures, complicating the charging process.
Innovation Solution
A charging plug and cable assembly with a movable conductor and cable sheath design, allowing for rotational flexibility without sliding contacts, incorporating a cavity for conductor movement and cooling medium circulation, and a holder that enables a limited +/−60° rotation, along with ergonomic features and impact-resistant elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the charging cable is made rigid with power and signal cables, cooling lines and mechanical protective elements, then the cable has sufficient structural strength and protection, but the cable becomes torsionally stiff and requires significant user effort to twist during insertion
Solution Approach 1:
The charging cable is divided into multiple independent segments: power cables, signal cables, cooling lines, and mechanical protective elements, all arranged in parallel within the cable conduit. This segmentation allows each component to maintain its own mechanical properties while working together as a unified structure, reducing overall torsional stiffness compared to a solid rigid cable.
Solution Approach 2:
The cable components are arranged in a multi-dimensional spatial configuration within the cable conduit, with power cables, signal cables, and cooling lines positioned at different radial and axial positions. This three-dimensional arrangement distributes mechanical stresses more effectively and reduces the cable's resistance to twisting motions during insertion.
2Ease of operation
If unlimited rotatability is achieved using sliding contacts at the transition between charging cable and charging plug, then the charging plug can rotate freely in the circumferential direction, but sliding contacts cannot be easily realized with high currents and have limited service life
Solution Approach 1:
The connector design incorporates a rotatable holder that allows the charging plug to rotate relative to the charging cable by +/- 60 degrees. This dynamic rotational capability is achieved through a mechanical hinge structure with defined rotation limits, eliminating the need for sliding contacts while maintaining reliable electrical connections through flexible cable segments that can accommodate the rotational movement.
Solution Approach 2:
The holder is pre-configured with defined rotation limits of +/- 60 degrees, allowing the charging plug to be rotated to the correct orientation before insertion. This preliminary rotational adjustment prevents excessive twisting during the insertion process and protects the electrical connections from damage.
3Ease of operation
If the charging plug is designed with complicated rotatable structures for unlimited rotation, then rotational freedom is achieved, but the charging plug becomes susceptible to damage by falling and requires more space
Solution Approach 1:
The holder incorporates a controlled rotational mechanism with defined +/- 60 degree limits, providing sufficient rotational freedom for proper connector alignment while preventing excessive rotation that could lead to damage. The mechanical hinge structure with integrated strain relief absorbs impact forces from drops and prevents the fragile electrical connections from breaking.
Solution Approach 2:
The connector design includes integrated strain relief elements and a robust holder structure that provide mechanical protection before damage can occur. The holder's hinge mechanism includes built-in flexibility and impact absorption capabilities that cushion against falling and prevent damage to the electrical connections and cooling lines.
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
Reduces the force required for plugging the charging plug, enhances ergonomics, and protects against damage, achieving a service life of 15,000 operations with improved torsional flexibility and cooling efficiency.
Implementation Method 1
The cavity between the at least one conductor and the cable sheath can be used to conduct a cooling medium through the cable sheath, which circulates around the conductor in the circumferential direction, at least in certain areas, and cools it in the process.
Data Source
AI summary
An assembly (1) with a charging plug (2) and a charging cable (3) attached thereto for a charging column for charging electric vehicles. The charging cable (3) has a cable sheath (4) and a plurality of conductors (5) movably arranged therein, the charging plug (2) including a plug housing (6) on which plug contacts (8) interconnected to the conductors (5) are arranged at a front end (7). Furthermore, a holder (10), to which the cable sheath (4) of the charging cable (3) is fastened, is arranged at a rear end (9) of the charging plug (2), wherein the holder (10) is arranged rotatably about a longitudinal axis (11) of the plug housing (6) by an angle of rotation (a) relative to the plug housing (6).