The Structure Study And Optimization Of Annular Canted Spring Used In DC Charge Coupler Of Electric Vehicle

The design requirements of charge pile and charge coupler are needed higher while electric vehicles have developed rapidly in recent years.Annular canted spring which is a typical form of centrosymmetry contact in multi-point contact is used prevalently in power,aerospace and other industries with connector contact forms.The DC charge coupler of annular canted spring in electric vehicle requires that the temperature rise is not too high under large current condition which need smaller contact resistance,and the effect of contact force between the contacts on contact resistance is the most obvious with the size of the positive pressure is directly related to the contact plug force and plug life.The research and analysis for the DC charge coupler of annular canted spring are systematical and deep in this project.First of all,contact force theory analysis and the maximum stress point prediction of single coil spring are studied with the Mohr'S theorem and bending beam analysis,while the contact force,separating force and the images of stress and strain of the structure can be obtained with static finite element analysis.Then the actual separation force is obtained by the plug test.Secondly,the temperature rise of the charge coupler is analyzed by means of heat conduction and heat convection with the body resistance,contact resistance of the structure and the theoretical temperature rise value calculated.The data calculated before is accordance with the standard plug of electric vehicle DC charge coupler.Finally,the optimal design and reliability analysis are combined to analyze the reliability optimal design of the annular canted spring with ANSYS Workbench.The reliability of the design is optimized to improve the mechanical reliability and get less maximum stress of annular canted spring charge coupler by the simulation and optimization of the with the condition of meeting the reliability constraints and structural geometry constraints and Maximum stress minimum as the optimization objective function.