EV Charge Port Cover With Hinged Access for Safe DC Fast Charging
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Solution Overview
Problem
Existing charging ports for electric vehicles, particularly agricultural work vehicles like tractors, lack sufficient safety measures and efficient charging capabilities, especially when using high voltage battery systems and DC Fast Charging systems.
Innovation Solution
The development of charging ports with added safety measures, including a cover with a fixed and movable portion connected by a hinge, allowing for fast DC charging and compatibility with both DC Fast Charging and AC grid power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover is added to protect the charging ports, then safety is improved, but device complexity increases
Solution Approach 1:
The cover is divided into a fixed portion and a movable portion that can independently function. The movable portion can be opened to expose charging ports when needed and closed to protect them, providing safety without requiring a completely complex removable cover system.
Solution Approach 2:
The movable portion of the cover automatically opens when a charging cable is inserted into the receptacle, and closes when the cable is removed. This self-actuating mechanism eliminates the need for manual operation or complex electronic control systems, maintaining simplicity while providing safety.
2Productivity
If DC Fast Charging capability is added, then charging speed is improved, but safety risks increase
Solution Approach 1:
The movable cover portion is positioned to automatically open before the charging cable makes full contact with the receptacle, and remains open during the entire charging process. This preliminary action ensures that the high-voltage DC charging ports are exposed only when charging is actively occurring, preventing accidental contact while enabling fast charging.
Solution Approach 2:
The movable cover portion acts as an intermediary barrier between the high-voltage DC charging ports and the external environment. It provides physical protection when not in use, reducing safety risks associated with exposed high-voltage terminals, while allowing rapid connection and disconnection of charging cables.
3Adaptability or versatility
If multiple DC charge ports are provided, then charging versatility is improved, but device complexity increases
Solution Approach 1:
Multiple DC charge ports are provided within a single unified cover structure, allowing the system to accept different charging cable types and configurations. The single movable cover portion protects all ports simultaneously, providing versatility without requiring separate covers for each port, thus avoiding increased complexity.
Data Source
AI summary
An electric vehicle (EV) includes a battery pack, at least one DC charge port to connect to a DC voltage source and charge the battery pack, and a cover that covers the at least one DC charge port. The cover includes a fixed portion and a movable portion that is connected to the fixed portion. The movable portion is movable about an axis. A receptacle of the at least one DC charge port is on a side of the axis spaced away from the fixed portion of the cover.