EV Charging Connector Latch Status Detection to Prevent Hot Disconnects

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Solution Overview

Problem

The existing electric vehicle (EV) charging systems lack a reliable method to detect whether the latch mechanism on charging connectors is operational, leading to potential hot disconnects, arcs, and damage to the connector and vehicle during charging, as well as safety risks for users.

Innovation Solution

A detection system integrated with the charging connector, utilizing magnetic sensors, photoelectric sensors, or wires to assess the operational status of the latch by measuring magnetic fields, optical properties, or electrical continuity, and generating alerts when the latch is non-operational.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a latch mechanism is used to secure the charging connector, then the connection security is improved, but the risk of latch failure and hot disconnect increases

Engineering Contradiction:

Improveconnection securityVSAvoidhot disconnect risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The detection system performs preliminary detection of the latch operational status before charging begins. The control system checks whether the latch is properly engaged and functional, and only allows charging to proceed if the latch status is confirmed as secure. This prevents hot disconnects by ensuring the connector is properly secured before high current flows.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The detection system continuously or periodically monitors the latch operational status during charging operations. When the latch status changes or becomes non-operational, the system provides feedback to the control system, which then terminates charging or generates alerts. This closed-loop feedback mechanism prevents hot disconnects by responding to latch failures in real-time.

Inventive Principle:

Principle #23Feedback

2Device complexity

If no detection system is installed, then the device complexity is reduced, but the ability to detect latch status is lost

Engineering Contradiction:

Improvesystem simplicityVSAvoidlatch status detection

Core Design Contradiction:

Device complexityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces complex mechanical detection mechanisms with simpler sensor-based systems. Magnetic sensors detect the position of a magnet attached to the latch, optical sensors detect the presence or position of optical elements on the latch, or simple electrical contacts detect latch engagement. These sensor-based approaches are less complex than mechanical switches or complex mechanical linkages while providing reliable detection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The detection system uses intermediary elements such as magnets, optical elements, or electrical contacts that are attached to or integrated with the latch mechanism. These intermediaries translate the mechanical state of the latch into detectable signals without requiring direct complex mechanical interaction between the latch and the control system.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If traditional latch mechanisms are used, then the manufacturing cost is reduced, but the safety risk during charging increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidsafety risk

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The detection system and control system work together to automatically monitor and respond to latch status without requiring external intervention. The system self-diagnoses latch problems and takes appropriate actions (terminating charging, generating alerts) to prevent safety incidents. This automated safety mechanism adds minimal cost while significantly reducing safety risks compared to traditional latch-only systems.

Inventive Principle:

Principle #25Self-service

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

Ensures safe charging by reliably determining the operational status of the latch, preventing hot disconnects and damage, and alerting operators to maintenance needs, thereby enhancing user safety and system integrity.

Implementation Method 1

a magnetic sensor coupled to a magnet, wherein the magnetic sensor measures a magnetic field associated with the magnet

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

a photoelectric sensor coupled to an optic fiber cable, wherein the photoelectric sensor measures optical properties associated with the latch

Methodology Applied

Scientific EffectPhotoelectric effect: Photoelectric Effect

Data Source

PatentUS20240181913A1Systems and Methods for Detecting an Operational Status of a Charging Connector of an Electric Vehicle Charging System

Publication Date: 2024.06.06 ABB E-MOBILITY BV

AI summary

A charging system of an electric vehicle is described. The charging system comprises a charging cable that is adapted to carry a charging connector located at a distal end of the charging cable, wherein the charging connector is configured to be controllably moveable and insertable into an EV charging portal of the EV, the charging connector comprising: a latch coupled to the charging connector, a detection system coupled to the latch, and a control system configured to: obtain, from the detection system, an indication, determine, based on the indication, whether the latch on the charging connector is operational or non-operational, and generate an alert based on determining that the latch on the charging connector is non-operational.