Charging Cable Plug Vibration for Cleaner Port Contacts
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Solution Overview
Problem
The degradation of charging ports and cables due to corrosion, dirt, and warping leads to reduced charging efficiency and potential harm to rechargeable batteries, especially in high-power systems like EVs and HEVs, resulting in longer charging times and battery degradation.
Innovation Solution
Implementing contact sensors and an electromechanical vibrator in the charging cable plug to detect contact and generate vibrations that loosen dirt, dust, and corrosive materials, improving the contact condition by enhancing the connection between the plug and port.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charging cable is repeatedly plugged and unplugged from the port, then the connection can be established for charging, but the contact condition degrades due to corrosion, dirt accumulation, and warping
Solution Approach 1:
An electromechanical vibrator is integrated into the charging cable plug to generate vibrations during the plugging process. These vibrations create relative movement between the contact surfaces of the plug and port, preventing dirt and corrosive materials from adhering to the contacts, thereby maintaining contact surface integrity despite repeated connections
Solution Approach 2:
The vibrator is activated before the plug fully contacts the port during insertion. This preliminary vibration action cleans the contact surfaces in advance, preventing contamination before it occurs, rather than attempting to clean after degradation has set in
2Productivity
If the contact condition between charging cable and port degrades, then the connection can still be established, but the charging efficiency decreases and battery life is reduced
Solution Approach 1:
The electromechanical vibrator generates vibrations that maintain clean contact surfaces between the plug and port. By preventing the accumulation of dirt and corrosion, the electrical connection remains optimal, ensuring high charging efficiency and minimizing energy loss during the charging process
Solution Approach 2:
The charging cable performs its own cleaning function through the integrated vibrator. The system uses its own operational moment (plugging in) to maintain its own contact surfaces, eliminating the need for separate maintenance and ensuring consistent charging performance
3Manufacturing precision
If the plug is vibrated at high frequency to remove dirt and corrosion, then the contact condition improves, but the user may have difficulty controlling the plugging process
Solution Approach 1:
The electromechanical vibrator operates in periodic bursts during the plugging process rather than continuously. This periodic activation provides sufficient vibration to clean contact surfaces while allowing the user to maintain control over the plugging action, balancing cleaning effectiveness with user operability
Solution Approach 2:
The vibrator operates at specific frequency parameters that are effective for loosening dirt and corrosion but not so intense as to create uncontrollable forces. By optimizing the vibration frequency and amplitude parameters, the system achieves cleaning effectiveness while maintaining user control during insertion
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system maintains or improves charging efficiency by ensuring secure and clean connections, reducing energy loss and extending battery life by preventing frequent charging needs, particularly in high-power systems.
Implementation Method 1
The electromechanical vibrator may be configured to vibrate the plug of the charging cable when the contact sensor determines the plug of the charging cable contacts the charging port. The vibrating of the plug of the charging cable may generate relative movement between the contact surfaces of the plug of the charging cable and prongs of the charging port based on transferred vibration from the electromechanical vibrator to the charging port via contact with the plug.
Implementation Method 2
the electromechanical vibrator may be configured to deliver vibrations at a frequency such that at least one of dirt, dust, and corrosive material is released from the charging port and the plug of the charging cable
Data Source
AI summary
Systems and methods are provided for improving a contact condition between a charging cable and a charging port. A charging cable may be plugged into a charging power to charge an electrical device. A charging cable may include a plug which may mate with prongs of a charging port. The plug may include sensors and a vibrator. The sensors may detect when a user intends to plug the charging cable into the charging port. Upon detection of intent to plug the charging cable into the charging port. The vibrator may be activated and may vibrate the plug. The vibration may generate relative movement between the prongs of the charging port and the plug. The movement may release dirt, dust, and corrosive materials from the charging port and plug, resulting in increased cleanliness. The movement may also assist in forming a more secure connection between the charging cable and plug.