Charging Inlet HMI Integration for Proximity Signal Detection
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Solution Overview
Problem
Conventional charging inlet assemblies for electric vehicles have a large pocket for the control circuit board, increasing size, complexity, and cost.
Innovation Solution
A charging inlet assembly with a housing that separates AC and DC sections, includes a human machine interface (HMI) assembly with integrated control circuit board and proximity resistor, and eliminates the need for a separate circuit board housing by integrating the resistor into the HMI assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate control circuit board with proximity circuit is retained within the housing, then the signaling protocol detection function is achieved, but the overall size, complexity and cost of the charging inlet assembly increases
Solution Approach 1:
The patent combines the proximity resistor with the HMI assembly into a single integrated component. The resistor is mounted directly on the HMI assembly circuit board, eliminating the need for a separate control circuit board with proximity circuit. This merging reduces the number of components, decreases overall assembly size, and simplifies the charging inlet assembly while maintaining the signaling protocol detection function.
2Reliability
If a large pocket for the control circuit board is provided in the housing, then the control circuit board can be retained, but the overall size of the charging inlet assembly increases
Solution Approach 1:
The control circuit board functions are integrated into the HMI assembly, which is mounted on the rear of the housing. This eliminates the need for a large dedicated pocket for a separate control circuit board, thereby reducing the housing volume while maintaining all necessary control and detection functions.
3Reliability
If a separate control circuit board with proximity resistor is used, then the proximity signal detection is achieved, but the manufacturing cost and assembly complexity increases
Solution Approach 1:
The proximity resistor is integrated into the HMI assembly rather than being a separate component on a dedicated control circuit board. This reduces the number of parts that need to be manufactured and assembled, lowering manufacturing costs and simplifying the assembly process while maintaining proximity signal detection capability.
Data Source
AI summary
A charging inlet assembly includes a housing having a DC section with DC terminals received in DC terminal channels for mating with a DC charging connector and AC terminals, including a proximity terminal, received in AC terminal channels for mating with an AC charging connector. The charging inlet assembly includes an HMI assembly coupled to the rear of the housing having a control circuit board, a charging indicator coupled to the control circuit board visible from the front of the housing to indicate a charging status of the charging inlet assembly, and a proximity resistor assembly coupled to the housing. The proximity resistor assembly includes a resistor coupled to the control circuit board and a cable connector connected between the control circuit board and the proximity terminal.