Service Plug Planar Guide Mechanism for Narrow EV Spaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing service plugs for electric vehicles are difficult to attach and detach in narrow, hard-to-visualize spaces due to the need for a gap that accommodates the height of guide walls and the plug body, limiting their use to only certain model lines and restricting the insertion of short-circuit terminals into circuit terminals.
Innovation Solution
A service plug design featuring a base member with an open hole and a restricting member to control the plug body's movement, along with a guide member for alignment, and a lever with a cam mechanism to facilitate the insertion of short-circuit terminals into circuit terminals, allowing the plug body to rotate and move within a plane parallel to the seat cushion, thus enabling easy attachment and detachment without requiring the plug body to move above the base plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If guide walls are provided on the base member to guide the plug body insertion, then the plug body can be positioned properly relative to the base member, but a large gap is required between the floor panel and seat cushion which limits the service plug to specific vehicle models
Solution Approach 1:
The patent changes the guiding mechanism from vertical guide walls to a planar guiding system using guide slots formed in the upper surface of the base member. The plug body moves within the plane of the base member rather than vertically above it, eliminating the need for height space while maintaining positioning accuracy through the slot geometry.
Solution Approach 2:
The patent extracts the guiding function from the vertical guide walls and implements it through planar guide slots on the base member surface. This separation allows the positioning function to be achieved without requiring vertical space, thus resolving the contradiction between positioning accuracy and space requirement.
2Manufacturing precision
If the plug body is moved to the position of guide walls for insertion, then proper alignment is achieved, but the required gap limits the service plug to only certain model lines
Solution Approach 1:
The patent transitions from a vertical alignment approach using guide walls to a planar alignment approach using guide slots. The plug body aligns with the circuit terminal by moving within the plane of the base member, achieving precise alignment without requiring vertical clearance that would limit model compatibility.
Solution Approach 2:
The patent implements a dynamic insertion process where the plug body is rotated and moved within the plane of the base member along guide slots, rather than being statically positioned above guide walls. This dynamic planar movement enables alignment in narrow spaces while maintaining precision.
3Ease of operation
If guide walls are reduced in height to fit narrow spaces, then the service plug can be installed in limited space, but the restriction of the plug body becomes insufficient and the short-circuit terminal cannot be inserted well
Solution Approach 1:
The patent eliminates the vertical dimension requirement by implementing guide slots in the planar surface of the base member. The plug body is restricted and guided within the plane through the slot geometry, achieving both narrow space compatibility and precise insertion accuracy without relying on vertical wall height.
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 and efficient attachment and detachment of the plug body to and from the base member in narrow, difficult-to-visualize spaces, ensuring proper alignment and insertion of short-circuit terminals into circuit terminals, even in limited spaces under a seat cushion, thereby expanding the plug's applicability to various vehicle models.
Implementation Method 1
a lever rotatably supported on the plug body; and a cam mechanism for pushing the plug body along the guide slot in response to rotation of the lever
Data Source
AI summary
A service plug includes: a base member in which a circuit terminal adapted to be connected to an electric circuit is provided and an open hole is formed in such a manner as to face the circuit terminal; a plug body comprising a short-circuit terminal adapted to be inserted into the circuit terminal; and a restricting member provided in the vicinity of the open hole of the base member for restricting movement of the plug body in a direction which intersects an inserting direction of the short-circuit terminal.