EV Charging Connector Decoupling Actuator Mechanism
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Solution Overview
Problem
The existing methods for recharging electric vehicles require manual intervention to connect and disconnect charging cables, which is tedious, especially when the vehicle is fully charged and the driver wants to leave without exiting the vehicle.
Innovation Solution
An automatic decoupling device is introduced, comprising a passive part on the connector side and an active part on the socket side, with rods driven by an actuator to extract the connector from the socket, allowing for wireless control when the battery is fully charged, thus enabling automatic disconnection without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual disconnection of charging cable is used, then connector can be reliably disconnected, but driver must exit vehicle to disconnect cable
Solution Approach 1:
The system enables self-service operation where the vehicle automatically disconnects the charging cable after battery recharging is complete. The control unit detects charging completion and automatically activates the actuator to extract the connector, eliminating the need for driver intervention and allowing the driver to remain in the vehicle.
Solution Approach 2:
The patent replaces the manual mechanical disconnection process with an automated electromechanical system. An actuator (electromagnetic, piezoelectric, or shape memory alloy) is used to translate push-buttons, which mechanically extract the connector from the socket automatically, substituting the driver's manual pulling action with an automated mechanical system.
2Extent of automation
If automatic decoupling device is added, then disconnection becomes automatic, but device complexity increases
Solution Approach 1:
The decoupling device is segmented into distinct functional components: a control unit for detecting charging completion, an actuator for generating extraction force, and multiple push-buttons arranged in a matrix for mechanical action. This segmentation allows each component to perform its specific function independently, simplifying the overall design and control logic.
Solution Approach 2:
The control unit serves multiple functions: it monitors battery charging status, detects when recharging is complete, and triggers the actuator for automatic disconnection. The push-button matrix serves both as a mechanical interface for the actuator and as a structural element that transmits force to extract the connector, combining multiple functions in a single component arrangement.
3Force
If push-button matrix is used, then connector extraction force is sufficient, but number of components increases
Solution Approach 1:
The push-button matrix uses multiple push-buttons (more than the minimum single action would require) to distribute and collectively generate sufficient extraction force. While this increases the number of components, each push-button can be actuated simultaneously by the actuator, and the cumulative force from multiple points ensures reliable connector extraction even when the connector is tightly engaged in the socket.
Solution Approach 2:
The multiple push-buttons are arranged in a compact matrix configuration where they work together as a unified mechanical system. The actuator translates all push-buttons simultaneously, merging their individual force contributions into a coordinated extraction action. This merging allows the system to generate sufficient total force while maintaining a compact structure that doesn't excessively increase device complexity.
Data Source
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AI summary
This device equips connection means comprising a connector (10), on the cable side of the charging station, and a socket, on the electric vehicle side. It comprises an active part (60) mounted on one element between the connector and the socket, and a passive part mounted on the other element, the active part comprising an actuator (65) and a plurality of rods (62) forming pushers adapted to be translated by the actuator to support the passive part of the decoupling device so as to generate a force to separate the connector from the socket.