Automatic Dust-Proof Cover for EV Battery Connectors
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Solution Overview
Problem
Quick change connectors for electric vehicle batteries are prone to contamination and deterioration during storage and transportation, leading to increased contact resistance and operational issues due to exposure to external dust and contaminants.
Innovation Solution
A fully-automatic dust proof system for quick change connectors, comprising a base with a slidably installed dust proof covering plate driven by an electric motor, controlled by a sensor system that automatically seals and opens the connector based on distance and pressure sensors to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the quick change connector is left exposed during battery pack storage and transportation, then the battery pack can be quickly installed and removed, but the connector becomes contaminated with dust and external contaminants leading to increased contact resistance and operational issues
Solution Approach 1:
The dust-proof covering plate is pre-positioned to automatically cover the quick change connector when the battery pack is detached from the electric vehicle body. This preliminary protective action prevents contaminant exposure before it can occur, eliminating the need for manual intervention while maintaining quick change capability.
Solution Approach 2:
The dust-proof covering plate acts as an intermediary element between the quick change connector and the external environment. It provides a physical barrier that mediates the interaction between the connector and contaminants, allowing the connector to remain protected during storage and transportation without affecting the quick change operation.
2Object-affected harmful factors
If a dust-proof covering plate is added to protect the quick change connector, then contaminant exposure is prevented, but the device complexity increases due to additional components and control systems
Solution Approach 1:
The dust-proof covering plate is merged with the battery pack structure, integrating the protective function into the existing battery pack design. The covering plate shares the same structural framework and control system as the battery pack, eliminating the need for separate protective devices and reducing overall system complexity.
Solution Approach 2:
The dust-proof covering plate is designed to automatically open and close based on the battery pack's connection state with the electric vehicle body. The system serves itself by using the existing connection/detachment motion to trigger the covering plate's movement, eliminating the need for additional actuators or complex control mechanisms.
3Device complexity
If the dust proof covering plate is manually operated, then the structure can be simple, but the automation level is low and requires manual intervention during battery pack operations
Solution Approach 1:
The system uses sensors to detect the connection state between the battery pack and the electric vehicle body, providing feedback to the control system. Based on this feedback, the control system automatically commands the dust-proof covering plate to open or close, achieving full automation without requiring manual intervention while maintaining relatively simple structural design.
Solution Approach 2:
The patent replaces manual mechanical operation with an automated control system that uses electrical signals and sensors to control the dust-proof covering plate's movement. This substitution of mechanical manual operation with an automated control system achieves high automation while keeping the mechanical structure relatively simple.
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
Effectively prevents contamination of quick change connectors by automatically sealing them during storage and transportation, ensuring reliable operation and extending their lifespan.
Implementation Method 1
an electric motor fixed on the base, for driving the dust proof covering plate to slide
Implementation Method 2
the base is provided with a second sensor, which is in electric connection with the control system and when the dust proof covering plate is completely closed or opened, the second sensor sends an in-position signal to the control system
Data Source
AI summary
A fully-automatic dust proof system for quick change connector of electric vehicle is provided. The fully-automatic dust proof system of the application comprises: a base provided at the quick change connector of the battery pack; a dust proof covering plate slidably installed onto the base; an electric motor fixed on the base; a power supply electrically connected with the electric motor; a control system for controlling the motor to drive the dust proof covering plate to slide; a distance sensor for monitoring relative distance between the battery pack and the electric vehicle; and a pressure sensor for monitoring whether the dust proof covering plate is in place or not.