EV Charge Port Door Linkage With Overload-Release Tilting Lever
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Solution Overview
Problem
Existing charge port door assemblies for electric vehicles are vulnerable to breakage when subjected to high-intensity loads, such as during a break-in attempt, due to the multiplication of forces through the actuation mechanism.
Innovation Solution
The charge port door assembly incorporates a tilting member with a tilting lever and an elastic biasing device, which allows the door to open without excessive load on the actuator when a high-intensity force is applied, thereby preventing actuator breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the actuation mechanism uses linkages to multiply the movement of the actuator, then the door can be opened with small actuator force, but the load on the actuator is multiplied when intense force is applied to the door
Solution Approach 1:
The tilting lever is designed to change its configuration dynamically between a blocking position (during normal operation) and an extended position (under intense load). This dynamic reconfiguration allows the mechanism to adapt its mechanical advantage ratio based on the applied load, reducing the force multiplication effect when high loads are present and protecting the actuator from excessive forces.
Solution Approach 2:
The mechanism changes the geometric parameters of the linkage system by altering the angle and position of the tilting lever. When the tilting lever moves from the blocking position to the extended position, it changes the effective lever arm lengths and the mechanical advantage ratio, thereby controlling the force transmission characteristics to protect the actuator.
2Reliability
If the charge port door is made secure against forced entry, then protection against break-in is improved, but the risk of actuator breakage under intense load increases
Solution Approach 1:
The patent converts the harmful effect of intense force applied to the door during break-in attempts into a beneficial protective mechanism. When excessive force is detected through the tilting lever's position change, the system automatically redirects this force through the extended configuration, preventing actuator breakage while still maintaining door security under normal conditions.
Solution Approach 2:
The tilting member acts as a pre-configured protective element that is ready to absorb and redirect excessive forces before they can damage the actuator. The elastic biasing device and the geometric design of the tilting lever create a cushioning effect that activates beforehand when load thresholds are exceeded.
3Device complexity
If the actuation system uses a fixed linkage configuration, then the mechanism is simple and reliable, but it cannot adapt to prevent actuator breakage under intense load
Solution Approach 1:
The patent introduces minimal dynamic elements (the tilting lever and elastic biasing device) into the otherwise fixed linkage system. These elements allow the mechanism to adapt its configuration based on load conditions while maintaining simplicity and reliability. The dynamic aspect is localized to the tilting lever, which only changes position when necessary, keeping the overall system relatively simple.
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 tilting member effectively safeguards the actuation system and the actuator from damage by allowing the door to open under intense loads, ensuring the assembly remains operational during potential security breaches.
Implementation Method 1
an elastic biasing device, configured to bias the tilting lever towards the blocking position
Data Source
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AI summary
The invention relates to a charge port door assembly (10) for a vehicle (1), comprising: - a charge port door (12); - an actuation system (16), configured to move the charge port door (12) between a closed position, in which the door (12) is intended to cover a charge port of a vehicle (1) and to remain flush with an outer surface of the vehicle (1), and an open position, in which the door (12) is intended to permit access to the charge port, the actuation system (16) comprising a linkage (18) connecting the door (12) to a support intended to be fixed relative to the vehicle (1), and an actuator (20) configured to actuate the linkage (18) to move the door (12), the linkage (18) comprising at least a first lever (22) rotatably coupled to the door (12), the actuation system (16) further comprising at least an actuation arm (28) being directly or indirectly connected at a first end (280) to an output member (200) of the actuator (20), and connected at an opposite, second end (282) to a tilting member (30), the actuation arm being movable between a first position corresponding to the closed position of the door (12) and a second position corresponding to the open position of the door (12), the tilting member (32) comprising a tilting lever (32) and an elastic biasing device (34), the tilting lever (32) being rotatably coupled to the actuation arm (28), and being rotatably coupled to the first lever (22), so as to be moveable relative to the first lever (22) between a blocking position and an extended position, the elastic biasing device (24) being configured to bias the tilting lever (32) towards the blocking position.