Charging Connector Lever Interlock for EV Battery Security
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Solution Overview
Problem
The existing charging connector for electric vehicles lacks a clear indication of its locking state, making it difficult for users to determine whether the lock is engaged, which may lead to accidental removal of the connector while it is still locked.
Innovation Solution
A charging connector design featuring a lever with a locking claw and a release button, where a lock system with an operation regulator prevents the release button from being pushed down when the lock is in a locking state, ensuring the user must explicitly unlock it to remove the connector, and includes options like a cylinder lock, biometric lock, or dial lock for secure access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is added to the charging connector, then the reliability of connection is improved, but the device complexity increases
Solution Approach 1:
The locking claw is integrated into the lever mechanism, and the operation regulator is nested within the connector housing. The locking components are embedded within the existing connector structure rather than added as separate external mechanisms, reducing overall complexity while maintaining locking functionality
Solution Approach 2:
The lever automatically engages the locking claw with the locking projection when the connector is fully inserted, providing self-locking functionality. The operation regulator automatically moves to prevent button operation when locked, eliminating the need for separate control systems
2Reliability
If an operation regulator is added to prevent button operation when locked, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The operation regulator is combined with the locking mechanism through the lever. When the lever rotates to engage the locking claw, it simultaneously moves the operation regulator to the blocking position, merging two functions into one integrated mechanism
Solution Approach 2:
The lever acts as an intermediary element that transmits the locking action to the operation regulator. The lever's rotation mechanically couples the locking engagement with the button operation prevention, creating a reliable interlock without complex control systems
3Object-affected harmful factors
If a lock system with key or biometric authentication is added, then security is improved, but the device complexity increases
Solution Approach 1:
The lock system is designed to accept multiple authentication methods (cylinder lock with key, biometric sensor with fingerprint, or dial lock with code) through the same basic mechanism structure. The operation regulator and lever assembly remain identical, while only the authentication interface varies, providing security versatility without proportional complexity increase
Data Source
AI summary
To provide a charging connector to prevent the charging connector from removing while a lock system is locked by helping a user recognize that 5 the lock system is locked. A charging connector B including: a lever 44 received in a connector case main body 23, and of which center part is pivotally supported; a locking claw 45b integrally formed with one end of the lever 44; and a release button 46a disposed at the other end of the lever 44, wherein 10 when the charging connector B is completely fitted into a secondary battery-side connector, the locking claw 45b is locked with a locking projection 19 provided at the secondary battery-side connector, and wherein when the release button 46a is pushed down, the locking between the locking claw and the locking projection is unlocked, and the charging connector B further including: a lock 15 system 100 having a lock device 101; and an operation regulator 102 which is moved to a preventing position to prevent the release button 46a from being pushed down when the lock device 101 is in a locking state, and moved to an allowing position to allow the release button 46a to be pressed down when the lock device 101 is in an unlocking state.