Vehicular Charge Port Door Powered Actuator Ice Clearance
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Solution Overview
Problem
Existing vehicular charging systems face challenges in efficiently opening and closing charge ports, particularly in scenarios with ice buildup or manual operation, where the actuator's torque is insufficient to break through ice and maintain a secure seal.
Innovation Solution
The implementation of an electrically operable actuator system with a detent mechanism and variable gear ratios, which provides high torque for closing and opening the charge port, and a clutch to protect against manual or abusive movement, ensuring reliable operation and ice clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a manual pivotable flap is used to cover the charge port, then the device complexity is reduced and ease of operation is improved, but the torque is insufficient to break through ice buildup and maintain a secure seal
Solution Approach 1:
The patent replaces the purely manual mechanical flap system with an electrically operable actuator system. The actuator includes a motor that drives a gear train to provide rotational motion and sufficient torque to the cover panel, enabling it to break through ice buildup and maintain a secure seal, while still allowing for manual operation when needed.
Solution Approach 2:
The patent implements a dynamic system where the cover panel can operate in multiple modes: manually pivoted by the user, or electrically actuated by the motor-driven gear train. The system adapts its operation mode based on conditions, providing both ease of manual operation and the reliability of powered actuation for ice clearance and secure sealing.
2Reliability
If an electrically operable actuator with gear train is implemented, then the torque is sufficient to break through ice and maintain secure seal, but the device complexity increases
Solution Approach 1:
The actuator system is designed to perform multiple functions: it can electrically actuate the cover panel for automatic operation, provide sufficient torque for ice clearance, maintain secure sealing, and still allow manual operation when needed. The gear train and motor assembly serve as a multi-functional solution that addresses reliability requirements while integrating various operational modes.
Solution Approach 2:
The patent merges the motor, gear train, and cover panel actuation mechanism into an integrated assembly. The output element of the actuator is directly coupled to the cover panel, combining the powered actuation system with the manual operation capability in a unified structure, thereby managing complexity through integration rather than separate components.
3Productivity
If the output element is always rotationally coupled to the output gear, then the actuator can always move the cover panel, but the system cannot withstand manual or abusive movement that could damage the motor
Solution Approach 1:
The patent extracts the motor from the direct load path by introducing a disengageable coupling mechanism. The output element can be rotationally coupled to the output gear when electrical operation is needed, but can be decoupled to protect the motor from manual or abusive movement. This separates the motor protection function from the continuous actuation capability.
Solution Approach 2:
The coupling between the output element and output gear is made dynamic rather than fixed. The system can transition between engaged and disengaged states, allowing the output element to be rotationally coupled to the output gear during normal electrical operation for productive movement, while being protectively decoupled during manual or abusive conditions to prevent motor damage.
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
The system effectively opens and closes the charge port with sufficient torque to break through ice and maintain a secure seal, enhancing user convenience and reducing the need for secondary mechanisms, while being compact and cost-effective.
Implementation Method 1
An actuator assembly is electrically operable to move the cover panel between the closed position and the opened position. The actuator assembly includes an electrically operable motor that, when electrically operated to move the cover panel between the closed position and the opened position, drives an output gear of the actuator assembly
Data Source
AI summary
A vehicular closure system includes a cover panel disposed at a charge port of a vehicle and movable between a closed position, where the cover panel conceals the charge port, and an opened position. An actuator is operable to move the cover panel between the closed and opened positions. A motor of the actuator rotates an output gear about an axis of rotation. An output element is connected to the cover panel and rotates about the axis of rotation as the cover panel moves. When the motor of the actuator is operated to move the cover panel, the output element rotates in tandem with the output gear. When the cover panel is manually moved, the output element rotates about the axis of rotation relative to the output gear.