Electromechanical Pawl for EV Charge Inlet Security
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional latching mechanisms for electric vehicle charge ports do not provide adequate security and control over the charging process, as they lack advanced features to prevent accidental disconnection during charging and do not ensure proper alignment of the charge connector.
Innovation Solution
A retractable latching pawl mechanism integrated into the charge inlet, which includes a lever assembly and solenoid actuator, controlled by a controller for pre-connection and de-coupling diagnostics, ensuring secure engagement and disengagement of the charge connector, and featuring a nub for tracking the connector's motion to prevent accidental insertion or removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional latching mechanism is used, then the charge connector can be freely inserted and removed, but the connector may be accidentally disconnected during charging and there is no control over the charging process
Solution Approach 1:
The patent replaces the purely mechanical conventional latching mechanism with an electromechanical system that uses a solenoid actuator to control the pawl's movement. This substitution allows electronic control and sensing to supplement the mechanical latching, providing diagnostic capabilities and controlled engagement/disengagement while maintaining the mechanical reliability of the connection.
Solution Approach 2:
The patent incorporates sensing contacts that detect the charge connector's position and provide feedback to the control system. The controller receives this feedback and can determine whether the connector is properly inserted and latched, enabling controlled disengagement only when appropriate conditions are met, thus preventing accidental disconnection during charging.
2Ease of operation
If the charge port door is externally mounted for easy access, then user access is convenient, but the charge inlet is exposed to weather and tampering
Solution Approach 1:
The patent uses a spring-loaded pawl that is pre-positioned to extend through the inlet surface, creating a protective barrier before the charge connector is even attempted to be inserted. This preliminary protective action prevents unauthorized access and protects the inlet from weather while still allowing legitimate charging operations when the pawl is retracted by the solenoid actuator.
3Reliability
If the pawl is held in the first position by a spring, then the connector is securely latched, but the connector cannot be inserted or removed
Solution Approach 1:
The patent introduces a solenoid actuator as an intermediary mechanism between the user's insertion/removal action and the pawl's latching state. When the charge connector is properly inserted, the solenoid actuator can be energized to temporarily retract the pawl, allowing the connector to be fully inserted or removed. This intermediary control provides secure latching during charging while enabling controlled insertion and removal operations.
4Reliability
If a latching mechanism is added to prevent accidental disconnection, then connection security is improved, but the device complexity and number of components increase
Solution Approach 1:
The patent designs the latching pawl to serve multiple functions: it acts as a mechanical latch to retain the connector, a sensing element that can detect connector presence and position, and a controlled barrier that can be retracted to allow insertion/removal. The solenoid actuator also serves dual purposes by controlling both the latching state and enabling the diagnostic functions. This multi-functionality reduces the need for separate components for each function.
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 retractable latching pawl mechanism enhances safety by preventing accidental disconnection during charging and ensures proper alignment, thereby improving the overall security and efficiency of the charging process.
Implementation Method 1
The latching mechanism may include a lever assembly and a solenoid actuator, where the retractable pawl is mechanically coupled to the lever assembly and the solenoid actuator controls movement of the retractable pawl from the first position to the second position via the lever assembly
Implementation Method 2
The latching mechanism may further include a spring coupled to the retractable pawl via the lever assembly, where the spring maintains the pawl in the first position when the solenoid actuator is un-energized
Data Source
AI summary
A charge connector latching mechanism integrated into a vehicle's charge inlet is provided, where the latching mechanism includes a retractable latching pawl. The retractable pawl is configured to be positioned in at least a first, default position where the pawl extends through an inlet surface of the charge inlet, and a second position where the pawl is retracted and does not extend through the inlet surface. In the first position the retractable pawl prevents insertion of a charge connector into the charge inlet if the charge connector is uncoupled from the inlet, and prevents removal of the charge connector if the charge connector is coupled to the inlet. In the second position the retractable pawl allows insertion/withdrawal of the charge connector into/from the charge inlet. The front surface of the retractable pawl may include a nub configured to fit within a recess within the front face of the charge connector.