Charge-Port Capture Gate Mechanism for Arc Flash Prevention
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Solution Overview
Problem
Conventional high-voltage interlock circuits and internal locking clips in battery electric vehicles (BEVs) fail to prevent arc flashes when disconnecting charge connectors from high-voltage direct current (HVDC) charge ports, due to time gaps between disconnection and detection, posing risks to operators and equipment.
Innovation Solution
A charge-port capture detection mechanism with a movable capture gate and mounting base, which captures the charge connector during charging and requires manual release, integrated with sensors to signal charging cessation upon gate removal, ensuring safe disconnection by prolonging the time to reduce current and prevent arc flashes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional HVIL circuits are used to detect disengagement, then the system can signal charging cessation, but the time gap between disconnection and detection allows arc flashes to occur
Solution Approach 1:
The capture gate mechanism performs preliminary action by physically preventing connector removal before the HVIL circuit can detect disengagement. The gate must be manually opened to release the connector, which triggers the HVIL circuit to detect the disconnection and cease charging, thereby eliminating the dangerous time gap between disconnection and detection.
2Reliability
If internal locking clips with push-button mechanisms are used, then the connector can be locked in-place during charging, but the locking mechanism itself can break and may not accommodate all connector sizes
Solution Approach 1:
The invention extracts the locking function from the connector itself and places it in a separate capture gate mechanism mounted on the charge port housing. This separates the locking function from the connector design, allowing the connector to be simpler and the locking mechanism to be independently optimized. The capture gate can accommodate different connector sizes without requiring changes to the connector itself.
3Object-affected harmful factors
If the capture gate is added to prevent arc flashes, then operator and equipment safety is improved, but the device complexity increases
Solution Approach 1:
The capture gate serves as an intermediary mechanical barrier between the operator and the high-voltage electrical connection. It mediates the disconnection process by requiring manual gate opening before connector removal, which triggers the HVIL circuit to detect disengagement and cease charging, thereby preventing arc flashes without requiring complex active control systems.
Data Source
AI summary
The disclosure describes technology that includes a charge-port capture detection mechanism, which has a mounting base and a capture gate. The mounting is connectable to a battery electric vehicle (BEV) at a location adjacent to a high-voltage, direct current (HVDC) charge-port. The capture gate is movably attached to the mounting base, the capture gate being moveable, relative to the mounting base, between a closed position in which the capture gate captures a charge connector of a charging cable engaged in the HVDC charge-port and an open position.