EV Charging Socket Interlock Structure for Safe High-Voltage Disconnect
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional electric vehicle charging sockets lack reliability and pose significant safety hazards due to their inability to automatically disconnect high-voltage circuits when the charging socket is detached or the rear cover is opened, potentially leading to operator safety risks.
Innovation Solution
A high-voltage interlock structure for electric vehicle charging sockets, which includes a charging socket body, detachable connectors and rear covers, and a control device connected to high-voltage interlock connectors. When these connectors are disconnected, the control device automatically disconnects the charging socket from the power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional charging socket structure is used, then the structure is simple, but the reliability is low and safety hazards exist
Solution Approach 1:
The charging socket is divided into multiple functional modules: charging socket body, connector, rear cover, and high-voltage interlock connectors. This segmentation allows independent control and monitoring of each component, improving reliability by enabling targeted safety interventions when specific parts are detached or malfunctioning.
Solution Approach 2:
High-voltage interlock connectors serve as intermediary components between the charging socket body and external elements (connector, rear cover). These intermediaries detect the connection status and transmit signals to the control device, enabling automatic disconnection of high-voltage circuits when safety conditions are not met, thus resolving the contradiction between simple structure and high reliability.
2Object-affected harmful factors
If automatic disconnection function is added, then safety is improved, but device complexity increases
Solution Approach 1:
The charging socket system performs self-protection through automatic disconnection functionality. When the control device detects disconnection of high-voltage interlock connectors, it automatically cuts off the high-voltage circuit without requiring external intervention, thereby improving operator safety while maintaining relatively simple structure.
Solution Approach 2:
The high-voltage interlock connectors provide continuous feedback to the control device about the connection status of the charging socket body, connector, and rear cover. This feedback mechanism enables the control device to make real-time decisions about circuit disconnection, improving safety through automated response to changing conditions.
3Ease of repair
If high-voltage interlock connectors are added, then safety during maintenance is improved, but manufacturing complexity increases
Solution Approach 1:
The maintenance safety feature is implemented through segmented high-voltage interlock connectors that can be independently installed and tested. This segmentation allows manufacturers to integrate the safety features into the existing production line in a modular manner, reducing the impact on manufacturing complexity while significantly improving maintenance safety.
Data Source
AI summary
A high-voltage interlock structure for an electric vehicle charging socket, and a charging apparatus include: a charging socket body, a connector, a rear cover, a control device, and high-voltage interlock connectors; in which the connector is detachably connected to the charging socket body; the rear cover is detachably connected to the charging socket body; the control device is disposed in the charging socket body; one of the high-voltage interlock connectors is disposed between the charging socket and the connector, and/or one of the high-voltage interlock connectors is disposed between the charging socket and the rear cover, and the high-voltage interlock connector is connected to a circuit where the control device is located; when any of the high-voltage interlock connectors is disconnected, the control device controls the charging socket to be disconnected from a power source.