Vehicle Charging Flap Fastener With Manual Pre-Opening Assembly
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Solution Overview
Problem
Existing charging flap systems for vehicles, particularly electric vehicles, require complex assembly procedures due to the hinge arm needing to be in an open position during installation, leading to increased assembly time and logistical disruptions.
Innovation Solution
An electrically operable charging flap system with a manually operable opening device on the charging flap fastener, allowing the flap to be opened manually before assembly, independent of the motor's power connection, facilitating faster and more efficient installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the charging flap system uses an electric motor to open and close the charging flap, then the automation and ease of operation are improved, but the assembly complexity increases because the hinge arm must be in the opened position during assembly
Solution Approach 1:
The system separates the electric motor from the manual opening function. The manual opening device operates independently of the motor, allowing the hinge arm to be manually positioned during assembly without requiring motor power or electrical connections.
Solution Approach 2:
The manual opening device enables preliminary positioning of the hinge arm in the opened state before the motor is installed or connected. This preliminary action simplifies assembly by allowing the charging flap to be mounted while the hinge arm is in the required position, without needing the motor operational.
2Reliability
If the hinge arm must be in the opened position for assembling the charging flap, then the assembly process becomes more restricted and time-consuming, but the reliability of motor-driven operation is maintained
Solution Approach 1:
The manual opening device allows assembly workers to independently position the hinge arm without requiring motor assistance or complex tooling. The device serves itself by providing a simple mechanical means (such as a pulling tab or engagement structure) that can be operated directly during assembly.
Solution Approach 2:
The system changes the operational parameter from requiring motor power to allowing manual operation during assembly. The manual opening device enables the hinge arm to be moved against spring force or gravitational force, changing the state from motor-dependent to manually operable during the assembly phase.
3Device complexity
If a push-push system with spring is used to open the charging flap mechanically, then the structure is simpler, but the ease of operation deteriorates due to manual effort required
Solution Approach 1:
The system merges two opening mechanisms: the manual opening device for initial positioning and the electric motor for automated operation. The spring-based push mechanism remains as the closing force, while the manual device provides the opening capability without requiring full motor installation.
Solution Approach 2:
The manual opening device acts as an intermediary mechanism between the assembly worker and the motor-driven system. It provides a simple interface (such as a pulling tab or engagement structure) that translates manual effort into hinge arm movement, bridging the gap between manual assembly needs and automated operation requirements.
Data Source
AI summary
An electrically operable charging flap system for a vehicle, in particular for an electric vehicle, includes a holding element for fastening in a vehicle, a charging flap fastener, which is movably fastened to the holding element, for fastening a charging flap, in order to move the charging flap to and fro between an open position and a closed position by way of an electric motor, and an opening device which is arranged on the charging flap fastener and is designed for manual raising of the charging flap fastener before the fastening of the charging flap. During installation, the holding element is fastened in the vehicle, and the charging flap fastener is raised manually into an open position. The charging flap is then fastened to the charging flap fastener while the charging flap fastener, after being raised manually, is in the open position.