Connector Mating Sensor Assembly for Full Charging Disconnect Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power connector systems for mobile devices, such as electric vehicles and mobile robots, do not adequately indicate when charging connectors are fully disconnected, leading to potential damage during movement.
Innovation Solution
A connector mating sensor assembly is integrated into the receive charging device to monitor the mating status of the power connectors, determining when the supply and receive power connectors are fully disconnected by sensing the presence of the supply housing relative to the receive housing, independent of the contact mating status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a first mate, last break sensor is used to indicate contact disconnection, then the contact disconnection status is detected, but the housing disconnection status is not indicated
Solution Approach 1:
The sensor system is segmented into two independent sensing functions: contact sensing (first mate, last break) and housing sensing (mating sensor assembly). This segmentation allows each sensor to specialize in detecting its specific parameter, with the housing sensor detecting the presence or absence of the supply housing relative to the receive housing, thereby providing complete disconnection status information.
Solution Approach 2:
A mating sensor assembly acts as an intermediary component between the supply housing and receive housing. This sensor assembly includes a sensor that detects the presence of the supply housing, providing indirect information about housing connection status. The sensor assembly mediates the detection function by converting physical housing presence into an electrical signal that indicates mating status.
2Productivity
If the mobile device moves prior to full disconnection of charging connectors, then charging can be interrupted, but damage to charging connectors occurs
Solution Approach 1:
The system performs preliminary detection of housing disconnection status before allowing device movement. The mating sensor assembly continuously monitors housing presence, and the system uses this information to determine when it is safe to interrupt charging and allow movement, preventing connector damage by ensuring complete disconnection before movement occurs.
Solution Approach 2:
The mating sensor assembly provides real-time feedback about housing connection status to the control system. This feedback mechanism allows the system to monitor the charging connection state continuously and make informed decisions about when to allow charging interruption and device movement, thereby protecting connectors from damage due to premature movement.
3Loss of information
If a sensor assembly is added to detect housing disconnection, then full disconnection status is indicated, but device complexity increases
Solution Approach 1:
The mating sensor assembly is designed to perform multiple functions within a single integrated structure. It detects housing presence, provides mating status indication, and can trigger charging interruption logic. This multi-functionality reduces the need for separate dedicated components for each function, thereby minimizing the increase in overall device complexity while providing complete disconnection status information.
Data Source
AI summary
A receive charging device includes a receive power connector having a receive housing with a mating end at a front having a receptacle configured to receive a supply power connector. The receive charging device includes receive power contacts for mating with supply power contacts of the supply power connector. The receive charging device includes a connector mating sensor assembly configured to be operably coupled to the supply power connector to indicate a mating status of the receive power connector with the supply power connector. The mating status is one of connected or disconnected.