EV Plug Study
This project is a study in ergonomics. From talking to users, one of the big problems with EV charging is managing the heavy cable. I sought to resolve that in my first design, creating a two-handed design. A foam prototype proved this concept be too large, and would likely damage the charging port on the vehicle.
I then swung the other direction, trying to combine a single-handed design. I fabricated a working model, and was satisfied with this design, but felt I could take it further. I created a rough CAD model to visualize a third design.
This is when the size became real.
The glue joint failed partway through, and this size felt a lot better than the full size.
Printing v2
Processing components for V2
I was using super glue and baking soda water as an accelerant.
When you need spacers but can't find the right size washers.
I had made the tolerances a little too large in some places, so I needed to add material to the parts.
Assembled.
The primary purpose for this model was printing a functional prototype. This is the interior of the plug.
V2, final version.
V3, utilizing a sort of doorknob design.
This version aimed to serve as more of a one-handed plug than an involved handle.
Due to the size of this design, it would likely incorporate a handle on the cord as well.