Motor-Driven Connector Locking Pin Position Sensing
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Solution Overview
Problem
Charging electric or hybrid vehicles via conventional charging plugs is time-consuming, prone to unauthorized disconnection, and may result in incomplete connections leading to impaired electrical contact and safety risks, while existing motor-driven locking devices are costly and lack reliability over the vehicle's lifecycle.
Innovation Solution
A cost-effective locking device driven by an electric motor, incorporating a movable locking pin with integrated switch means and resistors in a sensor circuit, allowing reliable detection of multiple positions and movements, including a simple conductor track design to determine the locking pin's position and prevent unauthorized disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a motor-driven locking device with continuous sensor monitoring is used to ensure secure connection, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines the sensor element circuit with the motor control circuit into a single integrated control unit. The sensor element's pull-up resistor is shared with the motor control, and the control unit processes both sensor signals and motor control signals, merging multiple functions into one device to reduce overall system complexity while maintaining reliability
Solution Approach 2:
The control unit serves multiple functions: it controls the motor operation, processes sensor element signals for position detection, monitors circuit states through the shared pull-up resistor, and manages the entire locking sequence. This multi-functional design eliminates the need for separate dedicated circuits for each function, reducing device complexity while ensuring reliable operation
2Measurement precision
If multiple sensor elements are added to detect additional locking pin positions, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent merges multiple position detection functions into a single sensor element by utilizing different switch means (first, second, and third switch means) that can be operated by the locking pin at different positions. The control unit integrates the signals from these switch means and the sensor element, combining multiple detection capabilities into one unified circuit rather than using separate sensor elements for each position
Solution Approach 2:
The single sensor element serves multiple detection purposes by working in conjunction with the different switch means. The same sensor element circuit detects the locking pin position at various stages of the locking process by monitoring the states of different switch means, making the sensor system multi-functional without requiring multiple separate sensor elements
3Ease of operation
If manual plugging is used to reduce device complexity, then ease of operation is improved, but connection reliability deteriorates due to incomplete connection and vibration resistance issues
Solution Approach 1:
The locking pin is designed to automatically engage and lock the electrical connection once the plug is inserted, without requiring manual locking actions. The motor-driven locking mechanism automatically moves the locking pin to secure the connection, ensuring proper engagement before the user completes the plugging operation, thereby guaranteeing connection reliability while maintaining ease of operation
Solution Approach 2:
The sensor element provides real-time feedback to the control unit about the locking pin position and connection status. The control unit monitors this feedback and can verify that the locking pin has reached its locked position, ensuring that the electrical connection is properly secured. This feedback mechanism guarantees connection reliability while the entire process remains automated and easy to operate
Data Source
AI summary
A locking device of an electrical connector half, which locking device is driven by an electric motor, for establishing an electrical connection to another electrical connector half to charge an electric or hybrid vehicle by plugging the other electrical connector half into the first-mentioned electrical connector half, having a movable locking pin for locking in the other electrical connector half plugged into the electrical connector half, and a sensor element arranged on the locking device, wherein, by means of the sensor element, at least one position, in particular an end position, of the locking pin can be determined, and wherein at least one switch means and a resistor are integrated in a circuit of the sensor element, such that at least one further position of the locking pin can be determined.