Spring-Loaded EV Charging Connector Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric vehicle charging systems face challenges such as increased equipment failure, maintenance costs, and exposure to damage and vandalism, particularly with above-ground charging stations, and inefficiencies in in-ground charging due to moisture sealing issues and limited power capacity of induction charging.
Innovation Solution
A below-ground charging station with a primary connector that automatically extends and connects to a secondary connector on the vehicle's underside, using a waterproof enclosure and alignment mechanisms to ensure secure and efficient charging, compatible with existing and future technologies, and capable of handling various vehicle misalignments and weather conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an above-ground robot is used to plug in the connector, then the connector can be automatically connected to the vehicle, but the device complexity and cost increase due to sensors, cameras, and control systems
Solution Approach 1:
The invention extracts the complex control system (sensors, cameras, computers) from the automation process and removes it entirely. Instead, a simple spring-loaded connector automatically engages with the vehicle connector through mechanical force alone, achieving automation without electronic control systems.
Solution Approach 2:
The spring-loaded connector is designed to automatically engage and disengage from the vehicle connector through its own mechanical properties. The spring force provides automatic connection when the vehicle is positioned correctly, and the connection can be automatically released by pulling the release tab, requiring no external control system.
2Extent of automation
If an above-ground robot is used to plug in the connector, then the connector can be automatically connected to the vehicle, but the maintenance cost and equipment failure risk increase
Solution Approach 1:
The connector is designed as a simple, inexpensive mechanical component that can be easily replaced if needed. The spring-loaded mechanism uses basic mechanical parts rather than expensive electronic components, making the system more reliable and cost-effective for long-term operation.
3Manufacturing precision
If an in-ground charging device with linear rails and motors is used, then precise alignment between connectors can be achieved, but the enclosure cannot be properly sealed from moisture
Solution Approach 1:
The invention removes the linear rails and motors from the in-ground charging device, replacing them with a simple spring-loaded connector that rises vertically from the ground. This eliminates the complex mechanical components that would compromise the waterproof seal while maintaining adequate alignment through the spring's mechanical guidance.
Solution Approach 2:
Instead of using active mechanical components (motors, rails) to achieve alignment, the invention uses a passive spring mechanism that relies on elastic deformation and mechanical force. The spring naturally guides the connector into alignment through its physical properties rather than requiring precise mechanical guidance systems.
4Ease of operation
If induction charging is used, then the vehicle can be charged without precise positioning, but the power capacity is limited to 11 KW and cannot support DC fast charging
Solution Approach 1:
The spring-loaded connector design can accommodate various connector types and configurations while maintaining the same simple mechanical engagement mechanism. This universal approach allows the system to support different charging standards and power levels, including future DC fast charging capabilities, without changing the basic engagement mechanism.
Data Source
AI summary
Provided in this disclosure is a charging apparatus for an electrical vehicle. When an electric vehicle is parked above the charging apparatus, a primary connector is slide-ably extended upwards and out of an enclosure in such a manner that it plugs into a secondary connector installed in the bottom of the chassis of the vehicle. The secondary connector includes an inverted cone-shaped component that is mounted to freely move horizontally in all directions from the center to engage the slide-ably extending portion of the primary connection and thereby achieve a final alignment of the primary and secondary connectors.