EV Charging Cable Manual Release Under Controller Faults
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Solution Overview
Problem
Existing vehicle charging systems face challenges in safely and reliably disengaging charging cables from vehicles due to error conditions such as software glitches, communication failures, or sensor malfunctions, which prevent automatic release of locking mechanisms.
Innovation Solution
A user-selectable manual disconnection option is implemented in the vehicle charging system, allowing users to manually disengage charging cables by resetting the charge controller, thereby terminating the charging session and unlocking the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If locking mechanisms are disabled automatically upon charging completion, then charging cable disengagement is convenient and safe, but the system fails to disengage when software errors or communication failures occur
Solution Approach 1:
The system provides self-service through automatic disengagement when charging completes normally, eliminating the need for manual intervention. The locking mechanism automatically disables and the cable can be removed without user action, making the system convenient while maintaining safety through automated control.
Solution Approach 2:
The system performs preliminary actions by attempting automatic disengagement before allowing manual intervention. When charging completes, the system automatically disables the locking mechanism and prepares for cable removal. Only if this preliminary automatic action fails due to errors does the manual override become necessary, maintaining the primary automated workflow.
2Ease of operation
If manual release mechanisms are made accessible to users, then disengagement is possible during error conditions, but safety risks increase due to potential accidental release during charging
Solution Approach 1:
The manual release mechanism's accessibility is made dynamic rather than static. The system monitors charging state and automatically adjusts the availability of manual release based on whether charging is active or completed. During charging, manual release remains inaccessible or disabled; after charging completion, it becomes accessible if automatic disengagement fails. This dynamic control prevents accidental release while enabling manual intervention when needed.
Solution Approach 2:
The system uses feedback from charging session status to control manual release accessibility. Sensors and controllers continuously monitor whether charging is active or completed, and this feedback determines whether the manual release mechanism is enabled or disabled. This feedback loop ensures manual release is only accessible when safe to use, preventing accidental discharge during active charging while allowing intervention when charging completes but automatic release fails.
3Reliability
If the system provides multiple disengagement methods (automatic and manual), then reliability under error conditions improves, but device complexity increases
Solution Approach 1:
The system merges automatic and manual disengagement methods into a unified charging system architecture. Both disengagement approaches share common control logic, sensors, and actuation mechanisms where possible. The manual release mechanism integrates with the existing locking system rather than being a completely separate subsystem, reducing overall complexity while providing redundant disengagement capability for improved reliability.
Data Source
AI summary
In order to ensure safe and reliable disconnection of charging cables from electric vehicles during occurrence of error conditions preventing normal disengagement of such charging cables, the systems and methods disclosed herein provide a vehicle charging system including a system controller configured to present via a display a user-selectable manual disconnection option when the vehicle is not receiving a charging current, receive an indication of a user selection of the manual disconnection option, and control a charge controller of the vehicle charging system to reset in order to terminate any charging session and to disengage the charging cable. In some embodiments, the charge controller may be configured or controlled to send a session termination signal to a vehicle charge controller of the vehicle either before resetting or as part of a startup process.