EV Charging Connector Coupling Mechanism for Live-Pin Safety
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Solution Overview
Problem
Existing electric vehicle chargers lack a reliable mechanism to prevent electricity flow when the charging connector is not coupled to a vehicle, posing safety hazards and failing to ensure user safety.
Innovation Solution
An electric vehicle charging connector with a coupling mechanism that enables electricity flow only when coupled to a vehicle, using sensors and a controller to detect coupling and disable power when uncoupled, employing a relay or mechanical switch to manage the electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the charging connector is designed without a coupling mechanism, then the device complexity is reduced, but safety hazards occur due to exposed live electrical contacts
Solution Approach 1:
The coupling mechanism is activated in advance to establish the electrical connection before power is supplied. The controller receives a coupling signal from the vehicle, then enables power flow through the relay or mechanical switch, ensuring the connector is properly coupled before electricity flows.
Solution Approach 2:
A coupling mechanism acts as an intermediary between the charging connector and the vehicle. This intermediary includes sensors that detect coupling status and a controller that manages power flow based on the detected status, preventing direct exposure of live contacts until properly connected.
2Reliability
If a coupling mechanism with sensors and controller is implemented, then safety is improved by preventing electrocution, but the device complexity increases
Solution Approach 1:
The coupling mechanism operates autonomously by detecting its own coupling status through sensors and automatically controlling power flow through the relay or mechanical switch. The system self-manages the safety function without requiring external intervention, reducing the need for additional control systems.
Solution Approach 2:
The patent employs a mechanical switch or relay as a simple mechanical component to control power flow, replacing the need for complex electronic control systems. This mechanical approach provides reliable safety functionality with minimal complexity.
3Device complexity
If the coupling mechanism uses a mechanical switch or relay, then the safety function is achieved with simple components, but the response time may be slower compared to electronic controls
Solution Approach 1:
The mechanical switch or relay is positioned and pre-configured to enable rapid engagement. The coupling mechanism is designed so that the mechanical components are ready to immediately establish or break the electrical connection upon coupling or uncoupling, minimizing response time despite the mechanical nature of the components.
Data Source
AI summary
An electric vehicle charging connector including a charging connector. The charging connector including a direct current pin and an alternating current pin. The electric vehicle charging connector also including a coupling mechanism configured to: couple the charging connector to an electric vehicle, enable a flow of electricity from the charging connector to the electric vehicle, and disable the flow of electricity from the charging connector to the electric vehicle.