EV Charger Casing, Orange Charger

06/2023 - 09/2023

Project Description

In my very first internship with Orange Charger, I was tasked with designing a new enclosure for an EVSE charger. The primary goal was to create a fully-defined Fusion 360 model with precise component spacing and tolerancing that could be directly adapted for injection molding tooling. The design needed to securely house delicate internal components (relay, bus bars, breaker box connection) while meeting aesthetic brand requirements.

Skills:

Software: Fusion 360 (Modeling, Assemblies), IGEMS CAM
Manufacturing: Waterjet Operation, Jig Fabrication, DFM
Project Management: Bottleneck Identification, Resource Optimization, Risk Mitigation

Key Contributions

Owned the end-to-end prototyping process for the charger enclosure, from initial concept to a dimensionally-accurate master model.
Identified and implemented solutions to critical project bottlenecks, reducing prototype iteration time by over 60%.
Used subscale prototyping to optimize snap-fit clips for the plug housing and tolerances for the backplate and insert, ensuring easy and robust assembly.

Early Hand-Sketch of System Architecture

Requirements and System Architecture

To kick off the project, Orange's CEO sat down with me for a brainstorming session. We talked over high level aesthetic and functional requirements and used quick hand sketches to lay down a first concept for the device architecture.

High Level Requirements:

fit within a 6" x 8" x 3.5" envelope
include a watertight front compartment for electronics which interfaces easily with the breaker box
3D printable for rapid prototyping but can be adjusted to optimize for injection molding
shaped for easy cable wrapping and includes a side holster for the charger plug
has space for an electrician to easily connect breaker box wires to the backplate from multiple potential access points

Flow-Chart Detailing Requirements by Component

System Structure & Design Process

I developed a modular assembly in Fusion 360, treating the internal components and their interfaces as the foundation of the design. To allow for quick updates to the model during prototyping, I defined everything using a series of master sketches. This top-down approach allowed me to update the entire model by changing a single dimension.

System Master Sketch

Backplate Side Profile

Insert Side Profile

Backplate 3D Sketch

Insert 3D Sketch

Minimizing Error:

To proactively catch interferences and avoid wasted print time, I meticulously analyzed part interfaces using section views before any prototyping began.

Male and Female Plug Section

Female Plug to Backplate Clip Section

Backplate to Insert Fit Section

Prototyping & Validation: A Targeted Approach

I executed three full prototype iterations, using subscale and section prints to test critical features early and often. This allowed for rapid iteration on complex interfaces without waiting for large, time-consuming prints.

Backplate-Insert Fit: Used quick subscale prints to verify tolerances and assembly alignment.
Plug Retention Clip: Iterated on the snap-fit geometry for the female plug by printing isolated sections of the backplate interface.
Cable Holster Integration: Refined the holster's fit and form through sectional prototypes, ensuring seamless integration with the main assembly.

Subscale Prints of Insert and Backplate

Overcoming Bottlenecks

The project timeline was jeopardized by a 4-week lead time for custom bus bars. I identified this as the critical path and developed an in-house solution:

Waterjet Fabrication: Used IGEMS CAM to program a waterjet, cutting bus bar profiles from existing conductive stock.
Jig Design & Bending: Designed and built a custom bending jig to form the flat profiles into their final 3D shapes. This intervention pulled in the project timeline by 25% and reduced prototype costs by 33%.

Results & Key Takeaway

Delivered Ahead of Schedule: Completed 3 thorough prototype iterations, cutting timeline by 25%.
Reduced Costs: In-house bus bar fabrication reduced prototype expenses by 33%.
Production-Ready Design: Supplied Orange Charger with a fully validated, modular design that met all component requirements and is easily adapted for injection molding.
Standing Return Offer: Successful project delivery resulted in a standing offer to return to Orange Charger.
Key Takeaway: I learned that a core part of mechanical design is designing the iteration process itself. Proactively identifying and creatively circumventing project constraints is a critical skill that directly impacts development velocity and final product quality.

Final CAD in Assembled Configuration

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