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Domestic EV
 

s1-6.png

Charger

Third Year

6 Weeks

To meet the exponentially growing demand for E.V chargers due to the incentivisation of hybrid/electric powertrains, we were tasked in this project to design a new commercially viable domestic unit. The key theme of this project was sustainability- the unit had to be as environmentally friendly as possible. This created a chance to learn material selector software and the built-in sustainability tool in Solidworks.

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The design also needed to fit within a chosen brand/vehicle ethos [the Ford Mustang Mach-E in my case], and consider correct internal component fit.

Stage 1: Ideation

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Research was carried out on potential sustainable material options that would still be fit for outdoor use [seen in Charts A and B]. Design directions were then worked up across a page which utilised some of the more favourable material options.

Stage 2: Concept Creation & Selection

A design from each of the directions was worked up onto a concept board. The decision on which to take forward came down to both myself and the client. 

 

'Pi' was ruled out due to the connotations of water with electricity. To decide between 'Flex' and 'Beam', an adapted Phillips Fast Five was produced to see which had more sustainable credentials [Beam]. 

EV Concept Board 1.tif

Stage 3: Refinement

EV Refine 1.tif

Refinement occurred on the unit and charge handle form [including 2D models], interior assembly [confidence of fit of components] and aesthetic appearance. 

Stage 4: CAD Model & Sustainability Work

A CAD model was produced of the final refined design in Solidworks. Whilst producing this, the Solidworks Sustainability tool was utilised to see what difference a variety of wall thicknesses and materials had on overall product environmental impact. This allowed me to settle on using a regrind HDPE polymer over aluminium on some components.

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A full LCA was also produced of the product at this stage.

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Stage 5: Presentation Boards

1-Hero Board EV Charger.tiff

Final Presentation Boards for my Ford Domestic EV Charger, the charge-e. Key features include:

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  • Eco-Plastic PE regrind and natural Silicone materials.

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  • Built-in Power Saving Devices/Phone Connectivity.

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  • Space saving design- Optimised for pallets.

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  • Adhesive free- Designed for disassembly/upgrades.

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