EV Charge Coupler Interlock for Housing Break Detection

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Solution Overview

Problem

Broken Combined Charging System (CCS) cables and charge couplers frequently incur field service visits and replacement costs due to damage, posing safety hazards and operational issues in electric vehicle charging infrastructure.

Innovation Solution

A charge coupler with a housing featuring a conductive member and a control system that senses breaks or detachment, utilizing sensors like accelerometers and gyroscopes to detect impacts, providing a safety interlock by disabling current flow and raising alarms, enabling remote monitoring for damaged components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a charge coupler housing is made robust and durable, then its strength and reliability are improved, but its weight and manufacturing complexity increase

Engineering Contradiction:

Improvehousing integrityVSAvoidhousing structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The housing is divided into multiple segments (first portion and second portion) that can be separately manufactured and assembled. This segmentation allows each portion to be optimized independently for strength while simplifying manufacturing processes and reducing overall complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The housing portions are coupled using a conductive member that serves both structural and electrical functions. This composite approach integrates mechanical coupling with electrical connectivity, reducing the need for separate components and simplifying the overall housing structure.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If safety interlock systems with multiple sensors are added to detect housing damage, then operator safety is improved, but device complexity and manufacturing costs increase

Engineering Contradiction:

Improvesafety hazards from broken contactsVSAvoidcontrol system

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The safety monitoring function is merged with the existing conductive member that couples the housing portions. The same conductive element that provides mechanical attachment also serves as the safety sensor, eliminating the need for separate sensor components and reducing system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive member performs multiple functions: it mechanically couples the housing portions together, provides electrical connectivity, and serves as a safety sensor to detect housing separation or damage. This multi-functionality reduces the overall component count and system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If remote monitoring capabilities are implemented to detect broken charge couplers, then infrastructure efficiency is improved, but device complexity and communication requirements increase

Engineering Contradiction:

Improvecharging infrastructure efficiencyVSAvoidmonitoring system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The control system continuously monitors the integrity of the conductive member and provides feedback about the housing condition. When damage or separation is detected, the system automatically sends alerts to remote monitoring systems, enabling proactive maintenance and improving infrastructure efficiency without requiring complex continuous monitoring of all components.

Inventive Principle:

Principle #23Feedback

4Reliability

If the conductive member is made highly conductive for electrical connectivity, then electrical performance is improved, but its susceptibility to breakage and damage increases

Engineering Contradiction:

Improveelectrical connectivityVSAvoidconductive member durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The conductive member is designed as a composite structure that combines highly conductive materials with reinforcement elements. This allows the member to maintain excellent electrical connectivity while the reinforced structure provides enhanced mechanical strength and resistance to breakage during handling and use.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11827113B2Charge coupler safety interlock systems and methods

Publication Date: 2023.11.28 RIVIAN HOLDINGS LLC

AI summary

A charge coupler adapted to be coupled to a charging inlet of an electric vehicle, the charge coupler including: a housing including a first portion adapted to be disposed around a first plurality of contacts and a second portion adapted to be disposed around a second plurality of contacts; a conductive member disposed between the first portion of the housing and the second portion of the housing; and a control system coupled to the conductive member and operable for sensing a break in the conductive member indicating damage to one or more of the first portion of the housing and the second portion of the housing or that the second portion of the housing is detached from the first portion of the housing. Optionally, the conductive member includes a conductive loop disposed around an inner periphery of the housing, the first plurality of contacts, and the second plurality of contacts.