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Master thesis on fast charger connector solution

Palm, Sebastian LU (2017) In CODEN:LUTEDX/TEIE EIE920 20162
Industrial Electrical Engineering and Automation
Abstract
Volvo Construction Equipment are investigating new machine concept that involve fast charging with high power. This should be done automatically and independent on humans. The thesis set out to develop and design a complete system solution for this, including the connector and the automated system for connection. The thesis is based on previous projects presented at LTH in various mechatronics courses.
An analysis is done over the application in question. Specific details are not mentioned due to secrecy.
The result of this work is that a single flexible arm is to be used, with one actuator. Mounted on this arm is the male connector. The flexible arm is guided, when extending, by a funnel leading to the female connector which is mounted... (More)
Volvo Construction Equipment are investigating new machine concept that involve fast charging with high power. This should be done automatically and independent on humans. The thesis set out to develop and design a complete system solution for this, including the connector and the automated system for connection. The thesis is based on previous projects presented at LTH in various mechatronics courses.
An analysis is done over the application in question. Specific details are not mentioned due to secrecy.
The result of this work is that a single flexible arm is to be used, with one actuator. Mounted on this arm is the male connector. The flexible arm is guided, when extending, by a funnel leading to the female connector which is mounted on the vehicle side. The automated system is only developed as a
concept due to limitations in time and resources.
The methodology used for the development of the connector is based on Ulrich and Eppinger’s well
renowned methodology for product development. From the application analysis it is decided that a plug-in connector is to be used. A final working prototype of the connector is developed and manufactured. Compared to the prototype previously presented at LTH in another project it is much smaller, around 50% in diameter. This is possible since a new concept is used for the male connector.
The length and diameter of the male connector is ~20 cm and ~5 cm.
The prototype connector is tested for various current levels measuring the temperature in different critical places within the connector. The objective of the testing is to find at what current the connector
levels out at a stable temperature around 100 degrees Celsius. This is found at 200A. This implies that it is possible to transfer 138 kW when charging with 3 phases AC and 400 V is done, and 512 kW when charging 2 phase DC with 640 V is done. (Less)
Popular Abstract
Volvo Construction Equipment are investigating new machine
concept that involve fast charging with high power. This
should be done automatically and independent on humans. The
thesis set out to develop and design a complete system solution
for this, including the connector and the automated system for
connection.
Few of the examples are designed with a broader market in
focus. Some can only be used for one or maybe two scenarios,
for example two different buses, but if a vehicle of different
size should be used a new system would be needed. This thesis
work ”Master thesis on fast charger connector solution” [1]
develop a plug in connector for an automated system for any
heavy vehicle between a local distribution truck to a... (More)
Volvo Construction Equipment are investigating new machine
concept that involve fast charging with high power. This
should be done automatically and independent on humans. The
thesis set out to develop and design a complete system solution
for this, including the connector and the automated system for
connection.
Few of the examples are designed with a broader market in
focus. Some can only be used for one or maybe two scenarios,
for example two different buses, but if a vehicle of different
size should be used a new system would be needed. This thesis
work ”Master thesis on fast charger connector solution” [1]
develop a plug in connector for an automated system for any
heavy vehicle between a local distribution truck to a dumper
in a mine. (Less)
Please use this url to cite or link to this publication:
author
Palm, Sebastian LU
supervisor
organization
course
EIE920 20162
year
type
H3 - Professional qualifications (4 Years - )
subject
keywords
Fast charging, High current connector, AC-charging, DC charging, Conductive charging, Plug-in connector, Small connector, Automated charging, Product development
publication/series
CODEN:LUTEDX/TEIE
report number
5396
language
English
id
8926490
alternative location
http://www.iea.lth.se/publications/MS-Theses/Full%20document/5396_full_document.pdf
date added to LUP
2019-03-15 12:12:21
date last changed
2019-03-15 12:12:21
@misc{8926490,
  abstract     = {Volvo Construction Equipment are investigating new machine concept that involve fast charging with high power. This should be done automatically and independent on humans. The thesis set out to develop and design a complete system solution for this, including the connector and the automated system for connection. The thesis is based on previous projects presented at LTH in various mechatronics courses.
An analysis is done over the application in question. Specific details are not mentioned due to secrecy.
The result of this work is that a single flexible arm is to be used, with one actuator. Mounted on this arm is the male connector. The flexible arm is guided, when extending, by a funnel leading to the female connector which is mounted on the vehicle side. The automated system is only developed as a
concept due to limitations in time and resources.
The methodology used for the development of the connector is based on Ulrich and Eppinger’s well
renowned methodology for product development. From the application analysis it is decided that a plug-in connector is to be used. A final working prototype of the connector is developed and manufactured. Compared to the prototype previously presented at LTH in another project it is much smaller, around 50% in diameter. This is possible since a new concept is used for the male connector.
The length and diameter of the male connector is ~20 cm and ~5 cm.
The prototype connector is tested for various current levels measuring the temperature in different critical places within the connector. The objective of the testing is to find at what current the connector
levels out at a stable temperature around 100 degrees Celsius. This is found at 200A. This implies that it is possible to transfer 138 kW when charging with 3 phases AC and 400 V is done, and 512 kW when charging 2 phase DC with 640 V is done.},
  author       = {Palm, Sebastian},
  keyword      = {Fast charging,High current connector,AC-charging,DC charging,Conductive charging,Plug-in connector,Small connector,Automated charging,Product development},
  language     = {eng},
  note         = {Student Paper},
  series       = {CODEN:LUTEDX/TEIE},
  title        = {Master thesis on fast charger connector solution},
  year         = {2017},
}