EV Charge Cord Lock via Door Signal Actuation
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Solution Overview
Problem
Existing charging systems for electric and hybrid electric vehicles lack a reliable mechanism to prevent accidental disconnection of charging plugs during battery charging, which can disrupt the charging process and increase complexity with additional switches or controls.
Innovation Solution
A charge cord lock system with a resiliently mounted catch and actuator, controlled by the vehicle's door lock/unlock mechanism, selectively locks the charge plug into the charging receptacle when the doors are locked and allows easy removal when unlocked, using a single additional actuator assembly without additional switches or controls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a charge plug is left unplugged or loosely connected, then the vehicle can be easily accessed and operated, but the charging process becomes unreliable and may be accidentally interrupted
Solution Approach 1:
The system performs preliminary locking action when the vehicle door is locked, automatically securing the charge plug in the receptacle before any accidental disconnection can occur. The controller receives a door lock signal and actuates the plunger to extend the catch into engagement with the retention flange, ensuring the plug is secured in advance of any potential disturbance.
Solution Approach 2:
The patent introduces an intermediary mechanism (the catch and plunger assembly) between the charge plug and the receptacle. This intermediary component mediates the connection by providing a positive mechanical lock through the catch engaging the retention flange, while being controlled by the door lock system, thus ensuring reliable charging without requiring direct manual intervention.
2Reliability
If a locking mechanism is added to prevent accidental disconnection, then charging reliability improves, but device complexity increases
Solution Approach 1:
The patent applies multi-functionality by making the door lock system control both the vehicle door locking and the charge plug retention. The existing door lock/unlock request mechanism is reused to trigger the plunger actuator, so the same control system performs multiple functions without adding independent controls or switches for the charging lock.
Solution Approach 2:
The system merges the door lock control function with the charge plug locking function. The controller integrates both functions by receiving door lock signals and simultaneously actuating both the door lock mechanism and the plunger to secure the charge plug, combining two separate functions into a unified control sequence.
3Reliability
If a locking mechanism with additional switches and controls is implemented, then charge plug retention reliability improves, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The system reuses the existing door lock/unlock request mechanism as the control input for the charge plug locking system. This multi-functional approach eliminates the need for separate switches or controls, reducing the number of components that need to be manufactured and assembled while maintaining reliable charge plug retention.
Solution Approach 2:
The system uses the vehicle's existing door lock control system to automatically manage the charge plug locking without requiring additional user inputs or separate control mechanisms. The door lock signal automatically triggers the plunger actuator to secure or release the charge plug, making the system self-managing and reducing manufacturing complexity.
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 system ensures the charge plug is securely locked during charging, preventing accidental disconnection while allowing intuitive operation and minimizing additional components, thus reducing cost and complexity.
Implementation Method 1
a catch resiliently mounted to a plunger
Data Source
AI summary
A charge cord lock system for a vehicle having rechargeable batteries. The system includes a charging receptacle; and a charge cord assembly having a charge plug slidably received in the charging receptacle and including a recess defining a retention flange. The system also includes a cord lock including a catch mounted to a plunger, with the plunger mounted to an actuator that moves the plunger toward and away from the charging receptacle, the catch engaged with the retention flange when the plunger is in an extended position and not engaged with the retention flange when the plunger is in a retracted position; and a controller in communication with a door lock mechanism and the actuator to cause the plunger to move to the retracted position when a door unlock signal is received and to cause the plunger to move to the extended position when a door lock signal is received.