Charge Port Door Actuation Lever for Forced-Load Release
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Solution Overview
Problem
Existing charge port door mechanisms in 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
A charge port door assembly with an actuation system that includes a linkage connecting the door to a support, an actuator, and an actuation lever assembly with an elastic biasing device. The actuation lever assembly allows the door to open without excessive load on the actuator when a high-intensity force is applied, preventing actuator breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the actuation mechanism uses linkages to multiply the movement generated by the actuator, then the door can be opened with small actuator force, but the actuator becomes vulnerable to breakage when intense load is applied to the door
Solution Approach 1:
The actuation lever is designed to dynamically change its configuration between an engagement position (for normal operation) and an extended position (for overload protection). This dynamic reconfiguration allows the system to adapt its mechanical advantage ratio based on the applied load, protecting the actuator during break-in attempts while maintaining ease of operation during normal use.
Solution Approach 2:
The actuation lever assembly acts as an intermediary between the door and the actuator. It includes a lever that can rotate between engagement and extended positions, and an elastic biasing device that mediates the force transmission. This intermediary mechanism allows the door to move without transmitting excessive loads to the actuator when forced open, while still enabling normal actuated operation.
2Reliability
If the actuation lever is designed to rotate between engagement and extended positions to protect the actuator, then the actuator is protected from breakage, but the mechanism complexity increases
Solution Approach 1:
The actuation lever assembly merges multiple functions into a single integrated component: it serves as both the force transmission element and the overload protection mechanism. The lever's ability to rotate between engagement and extended positions is built into the same component that transmits actuator force to the door, eliminating the need for separate protection mechanisms and reducing overall system complexity.
Solution Approach 2:
The actuation lever assembly is self-regulating through the elastic biasing device. When excessive force is applied to the door, the lever automatically rotates to the extended position, allowing the door to move without damaging the actuator. The elastic biasing device automatically returns the lever to the engagement position when normal conditions resume, eliminating the need for external control systems or complex sensing mechanisms.
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 actuation lever assembly effectively protects the actuation system and the actuator from damage by allowing the door to open under high-intensity loads without inducing excessive stress on the actuator, thereby enhancing security and reliability.
Implementation Method 1
the actuation lever assembly comprising an actuation lever and an elastic biasing device, the actuation lever being rotatably coupled at a first end to the output member of the actuator and being rotatably coupled at a second end to the actuation arm, the actuation lever being moveable relative to the output member between an engagement position and an extended position, the elastic biasing device being configured to bias the actuation lever towards the engagement 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 actuation system (16) further comprising at least an actuation arm (28), the actuation arm (28) being connected, at a first end (280), by the means of an actuation lever assembly (26), to an output member (200) of the actuator (20), and being directly or indirectly connected at an opposite, second end (282) to the door (12), the output member (200) 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 actuation lever assembly (26) comprising an actuation lever (30) and an elastic biasing device (32), the actuation lever (30) being rotatably coupled at a first end (300) to the output member (200) of the actuator (20) and being rotatably coupled at a second end (302) to the actuation arm (28), the actuation lever (30) being moveable relative to the output member (200) between an engagement position and an extended position, the elastic biasing device (32) being configured to bias the actuation lever (30) towards the engagement position.