Fueling India's EV Revolution:
Designing Next-Generation Charging Connectors
Client: 3SEV
As India charges toward an electric future, a critical piece of the puzzle was missing: a unified, homegrown solution for EV charging. 3SEV came to us with an ambitious vision: to design and develop India’s first line of EV charging connectors that would not only meet but exceed international standards. This was a monumental task, and we embraced the challenge of creating the essential hardware that would power the nation’s burgeoning EV ecosystem.
We took a deep dive into the world of EV charging, meticulously studying and designing various types of connectors for various power rating, including:
Type 6 Inlet and Connector
- DC charging connector ideal for bikes and small goods vehicles.
- E-Lock and Limit switch for close loop communication and operation.
- Mechanical latch for robust connections
Type 2 Connector
- AC charging connector ideal for cars and LMVs.
- Actuator for close loop communication and operation.
- Single and Three phase variants.
Beyond the core technology, we addressed every aspect of the user needs to ensure this device was truly practical for real-world use. We meticulously designed solutions for:
- Storage: Creating easy access hooks for handpieces and smart compartments for excess tubing to keep the device organized and ready for use.
- Mobility: Ensuring the device was lightweight and easy to transport, making mobile dentistry a realistic and convenient option. Device was designed to be adaptable between transport cart and the device with wheels for different user needs.
- Aesthetics: Crafting a medical device with a modern, professional appearance that instills confidence in both the user and the patient.
- Intuitive Interface: Developing a user interface that is easy to understand and operate, minimizing the learning curve for busy practitioners.
- Safety: Prioritizing user and patient safety in every design choice, adhering to all necessary medical standards.
- Reduced Noise: Engineering to damp the vibrations and minimise the pneumatic pump noises to best possible levels allowing the clinician to work in peace.
CCS2 Inlet and Connector
- DC charging connector ideal for cars and large vehicles.
- Actuator for close loop communication and operation.
- Single and Three phase variants.
The Challenge: Engineering for Durability and the Human Touch
The project was more than just engineering; it was about designing a robust, reliable, and user-friendly experience. Each connector presented a unique set
of challenges. We had to balance a range of critical considerations:
- Ergonomics: The connectors had to be comfortable and easy for any user to handle, regardless of their physical strength.
- User Safety: Adherence to the highest safety standards was paramount, with every detail designed to prevent electrical hazards.
- Structural Robustness: These connectors had to be built to last, withstanding daily use, accidental drops, and extreme environmental conditions like direct sunlight.
- Ingress Protection: We engineered each design to meet stringent IP requirements, protecting the internal components from dust and water.
- Reliable power terminals: Every connector for every power rating, the terminals were engineered and evolved for least contact resistance and efficient power transmission.
Beyond Design: A Partner in Innovation
Our role extended far beyond the drawing board. We served as 3SEV’s dedicated R&D wing, providing comprehensive support at every stage of the product lifecycle. From the initial industrial design concepts to detailed Design for Manufacturing (DFM), we were there every step of the way. We assisted with supplier identification and worked closely with manufacturers, addressing their queries and ensuring a seamless transition from prototype to mass production. The result is a family of connectors that are not only technologically advanced but also consistent in style and built to power India’s electric dreams.