Universal Contact Element Housing for Variable Terminal Spacing
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Solution Overview
Problem
Existing housings for contact elements in electric vehicle charging systems are not adaptable to different relative positions of contact elements, leading to increased production costs due to the need for separate housings for various configurations.
Innovation Solution
A modular housing design comprising two partial housings that can be assembled to form a common cavity, allowing for independent positioning and connection of electrical conductors to contact elements, regardless of their relative arrangement, thereby reducing the need for multiple housing designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate housing is produced for each kind of predefined relative position of contact elements, then the housing can be precisely adapted to specific contact element arrangements, but production costs increase and device complexity increases
Solution Approach 1:
The housing is designed with a universal structure that can accommodate multiple contact element arrangements through adjustable mounting positions and standardized interfaces. The housing includes multiple mounting holes and adjustment mechanisms that allow the same housing to be configured for different contact element spacings and orientations, eliminating the need for separate housings for each configuration.
Solution Approach 2:
The housing is divided into modular components that can be independently positioned and adjusted. The contact element mounting structure is segmented into adjustable sections, allowing each contact element to be positioned independently while using the same housing body. This modular approach enables a single housing design to serve multiple configuration needs.
2Manufacturing precision
If a separate housing is produced for each kind of predefined relative position of contact elements, then the housing can be precisely adapted to specific contact element arrangements, but device complexity increases
Solution Approach 1:
The housing incorporates universal mounting features and standardized interfaces that work across different contact element arrangements. Internal support structures and mounting brackets are designed to be repositionable, allowing the same housing to accommodate various contact element spacings and orientations without requiring different housing designs.
Solution Approach 2:
The housing includes adjustable and reconfigurable elements that allow dynamic adaptation to different contact element positions. Mounting positions can be shifted, and internal support structures can be repositioned within the housing, providing flexibility to accommodate different configurations without changing the housing itself.
3Ease of manufacture
If a universal housing is used for different contact element positions, then production costs are reduced and ease of manufacture is improved, but the ability to precisely adapt to specific arrangements may be compromised
Solution Approach 1:
The housing is segmented into adjustable modules with standardized interfaces. Each contact element mounting position is a separate, repositionable component that can be independently adjusted to achieve precise positioning while using the same housing body. This segmentation allows a single housing design to provide precise adaptation for multiple configurations.
Solution Approach 2:
The housing design incorporates adjustable parameters such as mounting hole positions, support structure locations, and interface configurations that can be changed to match different contact element arrangements. These parameter adjustments allow the universal housing to achieve precise adaptation without requiring different housing designs for each configuration.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a housing (1) for covering conductor-side connection points (17, 43) of at least two contact elements (19, 41) and for receiving in sections at least two electrical conductors (11, 33) as well as connection assemblies (15, 37) for connecting the electrical conductors (11, 33) to the contact elements (19, 41). In order to obtain a universal housing (1) that can cover pairs of contact elements (19, 41) that are spaced differently from one another, a housing (1) comprising a first partial housing (3) and a second partial housing (5) is provided, where the partial housings (3, 5) complement one another in an assembled state to form the housing (1), where the first partial housing (3) has a first conductor receptacle (7) which is configured to receive, at least in sections, a first electrical conductor (11) and a first connection assembly (15) for connecting the first electrical conductor (11) to a first contact element (19) and is provided with a passage opening (55) for a second contact element (41), where the second partial housing (5) has a second conductor receptacle (9) which is configured to receive, at least in sections, a second electrical conductor (33) and a second connection assembly (37) for connecting the second electrical conductor (33) to a second contact element (41), and where the second partial housing (5) is configured to abut against the first partial housing (3) in the region of the passage opening (55), and the second conductor receptacle (9) forms a common cavity (59) with the passage opening (55) in the assembled state.