Charging Port Lock Manual Release Cable Routing
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Solution Overview
Problem
Existing electrified vehicle charging ports often face issues with lock malfunctions, particularly when they become stuck in the 'stuck on plug' condition, requiring users to seek assistance for manual release, which complicates charging and maintenance.
Innovation Solution
A manual release mechanism is integrated into the charging port system, featuring a cable routed within the electrical harness with a handle accessible under the vehicle's hood, allowing users to manually release the lock by pulling the cable, thus overcoming stuck conditions without needing specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lock mechanism is integrated into the charging port to prevent theft and unintended separation, then security and reliability are improved, but the device complexity increases and the risk of lock malfunction increases
Solution Approach 1:
A manual release cable is introduced as an intermediary component between the user and the lock mechanism. The cable includes a handle accessible outside the charging port and transmits mechanical force through the electrical harness to actuate the lock, providing a simple interface that reduces operational complexity while maintaining security functionality.
Solution Approach 2:
The manual release cable is routed through and integrated within the electrical harness, nesting the release mechanism inside the existing harness structure. This eliminates the need for separate external routing and reduces overall system complexity by utilizing the existing structural pathway.
2Reliability
If the lock mechanism is made robust to prevent malfunction, then reliability is improved, but the ease of operation deteriorates when manual release is needed
Solution Approach 1:
The manual release cable acts as a mediator that transmits user input from an accessible location (handle under the hood) to the lock mechanism. This allows the lock to remain robust and secure while providing an easy-to-operate release mechanism that users can access without disassembling components or seeking specialized assistance.
3Device complexity
If the manual release cable is routed within the electrical harness, then the device complexity is reduced and assembly is simplified, but the cable protection and routing precision requirements increase
Solution Approach 1:
The manual release cable is nested within the electrical harness, utilizing the harness's existing structure for routing and protection. This integration simplifies assembly by treating the cable-harness combination as a single unit and reduces the need for separate routing channels, while the harness itself provides the necessary protection and structural guidance for the cable.
4Ease of operation
If a manual release mechanism is added to the charging port, then the ease of operation is improved for stuck conditions, but the device complexity increases
Solution Approach 1:
The manual release cable serves as a simple intermediary mechanism that adds minimal complexity to the charging port structure. By using a cable-and-handle system rather than a complex mechanical release mechanism, the solution improves ease of operation while keeping the added structural complexity to a minimum.
Solution Approach 2:
The electrical harness serves multiple functions: it provides electrical connectivity between the charging port and battery assembly, and simultaneously serves as the routing pathway and protective conduit for the manual release cable. This multi-functionality reduces the need for additional dedicated structures, thereby minimizing the increase in device complexity.
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
This solution simplifies the assembly and maintenance process by providing a convenient, accessible means to release the charging port lock, reducing reliance on external assistance and enhancing user convenience while ensuring secure charging operations.
Implementation Method 1
a manual release cable connected to the lock and routed at least partially within the electrical harness
Data Source
AI summary
An electrified vehicle according to a non-limiting aspect of the present disclosure includes, among other things, a charging port including a lock, an electrical harness electrically coupled to the charging port, a battery assembly electrically coupled to the charging port by the electrical harness, and a manual release cable connected to the lock and routed along the electrical harness. This disclosure also relates to a method.