EV Charging Connector Shutter Locking for Vandal Resistance
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Solution Overview
Problem
Commercially available Type 2 connectors for electric vehicle charging lack a unified, reliable mechanism for vandal resistance and plug locking, which compromises safety and ease of use.
Innovation Solution
A compact electrical connector with a single actuator-based locking mechanism that uses a lever and actuation motor to control shutter opening and locking, incorporating buttons and springs to ensure shutters remain closed unless a plug is inserted, and a lip-shaped gasket for IP sealing, compliant with EN 62196 Type 2 standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate mechanisms are used for vandal protection and plug locking, then each function can be independently optimized, but the device complexity increases and reliability decreases
Solution Approach 1:
The patent combines the vandal protection shutter mechanism and the plug locking mechanism into a single integrated system. The shutter assembly includes shutter members that can cover receptacles for vandal protection, while the locking mechanism uses a locking member that engages with the plug to prevent removal. These functions are coordinated through a unified control system that manages both shutter opening/closing and plug locking/unlocking, thereby reducing overall device complexity while maintaining both security functions.
Solution Approach 2:
The control system is designed to perform multiple functions: it controls the shutter members to open/close for vandal protection, manages the locking member to lock/unlock the plug, and coordinates these actions based on authentication status and plug insertion detection. This multi-functional approach eliminates the need for separate independent mechanisms, reducing complexity while ensuring both vandal resistance and secure plug locking operate reliably together.
2Device complexity
If a unified locking mechanism is used for both vandal protection and plug locking, then device complexity is reduced, but the ease of operation may be compromised
Solution Approach 1:
The shutter members are designed to be dynamically controllable, transitioning between closed (vandal protection) and open (access) positions based on authentication and plug insertion status. The locking member similarly transitions between locked and unlocked states. This dynamic behavior is managed through coordinated control that automatically adjusts the system state based on sensor input, making operation intuitive and easy for the user while maintaining security.
Solution Approach 2:
The control system incorporates feedback mechanisms that detect plug insertion and authentication status, automatically triggering the appropriate sequence of shutter opening and locking engagement. This feedback-driven automation simplifies user interaction, as the system responds automatically to user actions without requiring complex manual operation sequences, thereby maintaining ease of operation despite the integrated multi-functional design.
3Object-affected harmful factors
If shutters are designed to remain closed by default for vandal resistance, then security is improved, but accessibility for legitimate use requires additional authentication steps
Solution Approach 1:
The shutter members are pre-positioned in the closed state to provide default vandal protection. The control system is pre-configured to monitor for authentication events and plug insertion. When authentication is successfully performed, the system automatically executes the preliminary action of opening the shutters before plug insertion, and subsequently engages the locking mechanism. This preliminary positioning and automated sequencing ensures security is maintained by default while enabling quick access for authenticated users without requiring multiple manual steps.
Data Source
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AI summary
An electrical connector has a casing provided with a front opening and adapted to receive at the rear a female contact body in which a plug inserted in the front opening can engage; the female contacts are protected by a pair of shutters that prevent access to the female contacts when the shutters are in the closed position; a locking mechanism controls the opening of the shutters and the locking of the plug when it is inserted in the female contact body; the locking mechanism has a locking frame adapted to lock and unlock the movement of the shutters; the locking frame moves transversely with respect to the direction of motion of the shutters and defines at least one locking position and at least one unlocked position; the locking frame prevents or allows the movement of the shutters respectively in said locking or unlocked position; each shutter has at least one locking button; each locking button defines an interference position which prevents the movement of the shutter with respect to the locking frame, and a noninterference position, which allows the movement of the shutter with respect to the locking frame; each locking button is made to pass from the interference position to the noninterference position by inserting the plug.