Master thesis on fast charger connector solution

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.