Actuator Module Optical Position Detection for E-Mobility
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Solution Overview
Problem
Existing actuator modules for electric connections in e-mobility vehicles fail to reliably detect the status of the locking mechanism and minimize mechanical influence, leading to potential arcing and damage during charging, while also requiring optimization of installation space and component lifetime.
Innovation Solution
An actuator module with a movable locking member, a drive unit, and a position detection system using optical sensors, specifically fork light barriers, to contactlessly determine the position of the locking member, allowing for secure connection and disconnection, and providing multiple state detection capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical position detection methods are used for the locking member, then the detection mechanism is simple, but mechanical influence and wear occur reducing reliability
Solution Approach 1:
The patent replaces mechanical position detection methods with optical sensors (fork light barriers) that detect the locking member position contactlessly using light beams. This substitution eliminates mechanical contact between the detection system and locking member, preventing wear and mechanical influence while maintaining reliable position detection throughout the actuator module's operational life.
2Measurement precision
If multiple sensors are used to detect intermediate positions, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent divides the locking member's travel path into distinct segments (unlocked position, intermediate positions, locked position) and places optical sensors at specific locations along the direction of movement to detect each segment. This segmentation approach enables precise detection of multiple positions including intermediate states without requiring a single complex sensor system.
Solution Approach 2:
The patent introduces trigger members that extend from the locking member and interact with the optical sensors. These trigger members serve as intermediaries that translate the locking member's position into detectable optical signals, allowing precise position detection while keeping the sensor system relatively simple and modular.
3Duration of action of stationary object
If contactless optical detection is used, then mechanical wear is reduced extending component lifetime, but installation space requirements increase
Solution Approach 1:
The patent integrates the optical sensors and trigger members within the existing actuator module housing, nesting the detection system components within the available internal space. The trigger members extend from the locking member into the sensor detection zones, allowing compact arrangement that minimizes additional installation space while enabling contactless detection throughout the module's operational life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures reliable detection of the locking mechanism status without mechanical influence, preventing unintended disconnections, optimizing installation space, and extending component lifetime by accurately determining the locked, unlocked, and intermediate states of the actuator module.
Implementation Method 1
a position detection unit for determining the position of the locking member
Data Source
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AI summary
The invention relates to an actuator module (1) for locking an electric connection (87), such as a charge inlet (83), in particular of e-mobility vehicles (85). Solutions of the art generally apply mechanical sensors influencing the actuator module (1) mechanically and may reduce the lifetime of the actuator module (1). To solve these problems, an actuator module (1) is provided which comprises a locking member (43) which is movable from an unlocked position (5) to a locked position (9) along a direction of movement (25), a drive unit (47) for moving the locking member (43) from the unlocked to the locked position (9), and a position detection unit (59) for determining the position of the locking member (43), wherein the position detection unit (59) comprises at least one optical sensor (11) for detecting an object (22) in a detection zone (37), the actuator module (1) further comprising a trigger member (23), the trigger member (23) being located in the detection zone (37) in at least one of the unlocked position (5) and the locked position (9) of the locking member (43).