Electric Fuel Filler Flap with Intermediate Charging Position
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Solution Overview
Problem
Electric vehicle charging processes are vulnerable to external weather influences and vandalism due to the exposure of charging components, and existing tank flap mechanisms inadequately protect these components during prolonged charging sessions.
Innovation Solution
An electrically actuable tank flap device with a pivotable design, controlled by an electric motor and a control device, which moves from a closed to an open position and an intermediate position to protect the charging socket and fuel filler flap, using sensors to detect plug insertion and adjust the flap's position accordingly, and a self-locking worm gear for enhanced security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the tank flap is kept open during charging to allow access to the charging socket, then the charging process can proceed, but the charging components are exposed to weather influences and vandalism
Solution Approach 1:
The tank flap is designed to dynamically change its position between closed, intermediate, and fully open states based on the charging status. During charging, it automatically moves to an intermediate position that provides sufficient access for the charging socket while maintaining protection against environmental factors and vandalism.
Solution Approach 2:
The tank flap's movement range is segmented into multiple distinct positions: fully closed (for maximum protection), intermediate (for charging access with protection), and fully open (for complete access). This segmentation allows the system to optimize between protection and accessibility by selecting the appropriate position based on operational requirements.
2Object-affected harmful factors
If the tank flap is kept closed to protect the charging socket, then protection against weather and vandalism is improved, but access for charging becomes difficult
Solution Approach 1:
The system dynamically adjusts the tank flap position based on charging detection. When a charging plug is detected in the charging socket, the control unit automatically actuates the electric motor to move the tank flap to an intermediate position that balances protection with charging accessibility.
Solution Approach 2:
The control unit continuously monitors the charging socket status and provides feedback to the electric motor control. When charging is detected, the system responds by adjusting the tank flap to the intermediate position, and when charging is complete or interrupted, it returns to the closed position, creating a closed-loop control system.
3Ease of operation
If a fully open tank flap design is used to maximize charging access, then ease of operation is improved, but protection against weather influences and vandalism is lost
Solution Approach 1:
Instead of maintaining a permanently open position, the tank flap dynamically transitions to an intermediate position during charging operations. This intermediate position is optimized to provide the minimum necessary opening for charging access while maximizing protection, eliminating the need for full exposure.
Solution Approach 2:
The system applies partial action by opening the tank flap only to the extent necessary for charging access (intermediate position) rather than fully opening it. This partial opening provides sufficient access for the charging socket while maintaining adequate protection against environmental factors and potential vandalism.
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
The tank flap device effectively protects the charging components from weather and vandalism by partially closing the tank recess during charging, reducing exposure and enhancing security through precise positioning and locking mechanisms.
Implementation Method 1
an electric motor (8) and a control device (3). The control device (3) is designed to control the electric motor (8) in such a way that a motor shaft (8a) of the electric motor (8) rotates in a first direction of rotation and in an opposite, second direction of rotation
Implementation Method 2
A drive device is connected to the closure flap via a gear train, which can include a worm wheel
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
An electric fuel filler flap device (1) for a vehicle (2) comprises a fuel tank recess (4) having an opening (5) through which a charging socket (6) and/or a fuel filler neck is penetrated. It includes a control unit (3), an electric motor (8), and a pivotable fuel filler flap (7). The control unit (3) is configured to actuate the electric motor (8) such that a motor shaft (8a) of the electric motor (8) is rotatable in two directions of rotation, wherein a rotation of the motor shaft (8a) in a first direction of rotation causes the fuel filler flap (7) to pivot from a closed position to an open position, and wherein a rotation of the motor shaft (8a) in a second direction of rotation causes the fuel filler flap (7) to pivot back from the open position to the closed position.As soon as a charging plug (10) is inserted into the charging socket (6) and/or a fuel nozzle is inserted into the fuel filler neck, the electric motor (8) is controlled in such a way that it pivots the fuel filler flap (7) from the open position to a stored intermediate position in the direction of the closed position.