Rotating Contact Head for Safe EV Rapid Charging Connection
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Solution Overview
Problem
Existing rapid charging systems for electric vehicles require precise alignment and manual intervention, posing risks of unsafe connection sequences that can lead to short circuits and damage, especially when dealing with charging stations having converging guiding walls and conductive strips oriented in multiple planes.
Innovation Solution
A contact head with rotatably disposed electrical contacts and a resilient element, where an earthing contact initiates contact with the charging station's conductive strip first, followed by electrical and communication contacts, ensuring a safe and automatic connection sequence, compatible with various charging station geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual intervention and precise alignment are used for connection, then connection accuracy is improved, but operation complexity and safety risks increase
Solution Approach 1:
The connection system performs self-alignment and self-connection through the rotating arm mechanism that automatically orients the electrical contacts toward the charging station and establishes contact sequences without manual intervention, eliminating the need for precise manual alignment while maintaining connection accuracy
Solution Approach 2:
The earthing contact is positioned to make preliminary contact with the charging station before the main electrical contacts, pre-establishing a safe grounding connection that prevents short circuits during the subsequent automatic connection process
2Reliability
If automated connection sequence is implemented, then safety is improved, but device complexity increases
Solution Approach 1:
The connection system uses a dynamically rotating arm mechanism that automatically adjusts its orientation and contact sequence based on the relative position between the vehicle and charging station, achieving safe automated connection through motion-controlled contact establishment rather than static complex mechanisms
Solution Approach 2:
The connection process is segmented into distinct phases: earthing contact establishment, followed by main electrical contact connection, with each phase controlled by the rotational position of the arm, simplifying the control logic while ensuring safety through sequential operation
3Adaptability or versatility
If multiple contacts are arranged for different planes, then adaptability to charging stations is improved, but alignment precision requirements increase
Solution Approach 1:
The rotating arm mechanism dynamically adapts the orientation of multiple electrical contacts to match different charging station configurations, allowing the same physical structure to achieve precise alignment with various station geometries through rotational adjustment rather than requiring multiple precision-manufactured fixed configurations
Solution Approach 2:
The multi-contact arm structure serves multiple functions: it can connect to charging stations with converging guiding walls, parallel walls, or different orientations by rotating to the appropriate angle, making a single device adaptable to various charging infrastructure types without compromising alignment precision
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
Enables easy, safe, and automated connection to charging stations with converging guiding walls, reducing the risk of short circuits and minimizing driver intervention while maintaining a wide range of head installation flexibility.
Implementation Method 1
at least one resilient element for pressing the electrical contacts against at least two conductive strips
Implementation Method 2
the earthing contact contacts the conductive strip as the first of all contacts
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The subject matter of the present invention is a contact head for a current collector adapted for charging a vehicle equipped with an electric drive in rapid charging systems, comprising at least two oppositely arranged electrical contacts mounted on at least two pressing elements that are rotatably disposed on at least one axis of rotation with a limited angle of rotation and having at least one resilient element for pressing the electrical contacts against at least two conductive strips of a compatible contact device of a charging station, said conductive strips being arranged on opposite sides of the contact head and through which the power supply voltage is applied, wherein the pressing elements are formed as opposing arms (2, 3) - a first arm (3) and a second arm (2); at least one electrical contact (5) is provided on the first arm (3); at least one electrical contact (6) is provided on the second arm (2); at least one axis of rotation (4) around which the arms (2, 3) rotate is aligned essentially in the direction of the longitudinal axis of the vehicle, parallel to the direction of vehicle movement; wherein to the second arm (2), on an axis (13) parallel to the at least one axis of rotation (4), a third arm (8) is rotatably attached through a resilient element, on said third arm (8) an earthing contact (9) is arranged, the earthing contact (9) being in an extended position and protruding beyond the boundary of the head (1), so that when connecting the head (1) to the charging station, the earthing contact (9) contacts the conductive strip as the first of all contacts; wherein on one of the arms (2, 3), from the side facing the conductive strips, a communication contact (7) is provided. Moreover, the present invention also relates to a method of establishing electrically conductive connection between the charging station and the contact head (1).