Charging Socket Interlock Using Blind Plugs to Block Live-Part Access
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Solution Overview
Problem
Hybrid and electrified vehicles face safety risks due to live parts in charging contact sockets becoming electrified when not all sockets are connected, posing a danger if accessed accidentally during charging.
Innovation Solution
A method and arrangement that detect the presence of electric plugs or blind plugs in each socket, ensuring the switch in the EVSE station is only closed if all sockets have either a plug inserted, and locking plugs in place until the charging process is complete, preventing access to live parts by controlling the switch only when all sockets are properly connected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple charging contact sockets are provided in the vehicle, then charging flexibility and adaptability are improved, but the risk of accidental access to live parts increases when sockets are not properly connected
Solution Approach 1:
The system performs preliminary detection of plug presence in all charging sockets before enabling the charging process. The control unit checks whether plugs are properly inserted in required sockets, and only after successful verification does it close the switch to enable charging. This preliminary action prevents accidental access to live parts by ensuring proper connection before energizing the system.
Solution Approach 2:
The control unit continuously monitors the status of charging sockets and provides feedback control. It detects whether plugs are properly inserted and uses this information to control the switch state. The system only closes the switch when feedback confirms proper plug insertion in all required sockets, creating a closed-loop safety mechanism that prevents accidental access to live parts.
2Productivity
If the switch is closed to enable charging, then energy transfer efficiency is improved, but safety protection against accidental access to live parts is compromised
Solution Approach 1:
Before closing the switch to enable charging, the control unit performs preliminary verification that all required sockets have plugs properly inserted. This preliminary action ensures that the charging process only starts when safety conditions are met, preventing accidental access to live parts while maintaining efficient energy transfer once charging is authorized.
Solution Approach 2:
The control unit uses real-time feedback from plug presence detection to control the switch state. Charging current is only permitted when feedback confirms proper connection, creating a safety interlock that maintains both productivity and safety during the charging process.
3Ease of operation
If plugs can be freely removed from sockets, then ease of operation is improved, but safety protection against access to live parts is reduced
Solution Approach 1:
The system dynamically controls plug accessibility based on charging state. During active charging, the control unit prevents plug removal by maintaining switch closure and potentially engaging mechanical locking. When charging is stopped or suspended, the system dynamically changes state to allow safe plug removal. This dynamic behavior balances ease of operation with safety protection.
Solution Approach 2:
The control unit continuously monitors charging status and provides feedback control over plug accessibility. Plugs are only removable when feedback indicates that charging is not active or has been properly suspended, preventing accidental access to live parts while maintaining operational convenience during safe conditions.
Data Source
AI summary
An arrangement for preventing access to live parts in charging contact sockets of a hybrid or electrified vehicle having a plurality of such sockets each connectable to an external source of electric energy through a switch in an electric vehicle supply equipment station by inserting an electric plug in a socket for providing electric energy to batteries comprises blind plugs insertable into the sockets and the sockets are connected to each other and the batteries. A device is configured to sense presence of either an electric plug or a blind plug in each socket and the switch will be closed under the condition that either an electric plug or a blind plug is sensed by the device for all sockets and at least one of these plugs is an electric plug.