EV Charging Connector Locking Based on Power Flow Detection
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Solution Overview
Problem
Existing electrical aircraft charging systems face issues with the charging connector becoming detached or dislodged during charging, leading to inefficiencies and safety concerns due to current flow while unplugging.
Innovation Solution
A locking mechanism is integrated into the electric vehicle charging connector, which includes a sensor to detect power flow and automatically engage or disengage the locking mechanism based on power presence, ensuring secure coupling to the charging port.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a locking mechanism is added to prevent connector detachment, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The locking mechanism automatically engages when the connector is properly inserted into the charging port, without requiring manual intervention. The system uses the insertion force itself to trigger the locking action, making the locking process self-service and eliminating the need for additional control systems or user operations.
Solution Approach 2:
The patent replaces complex electronic locking systems with a simple mechanical locking mechanism that uses spring-loaded arms and corresponding notches. This mechanical approach achieves reliable locking through pure mechanical interaction between the connector and charging port, avoiding the need for motors, sensors, or electronic control circuits.
2Object-affected harmful factors
If automatic locking based on power detection is implemented, then safety is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is designed to engage automatically as soon as the connector is inserted and power flow is detected, before any charging operation begins. This preliminary locking action ensures that the connection is secured before any potentially harmful current flow occurs, preventing safety issues related to unplugging during charging.
Solution Approach 2:
The system uses a simple feedback mechanism where the presence or absence of power flow automatically controls the locking state. When power is detected, the locking mechanism engages; when power is absent, it disengages. This binary feedback system provides safety without requiring complex control logic or multiple sensors.
3Stability of the object's composition
If the locking mechanism is always engaged, then connection stability is improved, but ease of operation deteriorates
Solution Approach 1:
The locking mechanism dynamically adapts its state based on operational conditions. It is engaged during charging operations to maintain connection stability, but automatically disengages when charging is complete or power flow stops, allowing easy removal. This dynamic behavior provides both stability during use and ease of operation when needed.
Solution Approach 2:
The system uses power flow detection as an intermediary condition to control the locking state. Rather than locking or unlocking based on manual input or timing, the actual presence of electrical power serves as the mediator that automatically determines whether the connector should be locked or unlocked, providing intuitive operation aligned with the actual charging state.
Data Source
AI summary
An electric vehicle charging connector, including a set of pins, a sensor, and a controller. The set of pins may include a DC pin, wherein the DC pin is configured to supply DC power to a charging port, wherein the charging port comprises a locking mechanism. The sensor can detect power flow from the pins to the charging port. The controller is communicatively connected to the sensor and configured to receive a signal from the sensor and send a locking signal to a locking mechanism. The locking mechanism comprises an engaged state wherein the charging connector is mechanically coupled to the charging port and a disengaged state wherein the charging connector is mechanically uncoupled form the charging port, wherein the locking mechanism is configured to receive a locking signal from the controller of the charging connector and enter the engaged state.