Emergency Disconnection Cable Mechanism for EV Charging Inlet
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Solution Overview
Problem
Existing electric vehicle charging systems fail to ensure quick and reliable disconnection of the charging outlet from the inlet during emergency situations, particularly when the inlet actuator malfunctions.
Innovation Solution
An apparatus featuring a handle, emergency disconnection cable, and lever mechanism that allows for manual disconnection of the outlet by rotating the handle, which pulls the emergency disconnection cable to release the actuator pin and disconnect the outlet, utilizing a plate spring for automatic return to the original position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inlet actuator is used to disconnect the outlet, then the disconnection function is integrated into the charging system, but the system fails to ensure quick and reliable disconnection during emergency situations when the actuator malfunctions
Solution Approach 1:
The patent introduces an emergency disconnection cable as an intermediary mechanism that directly connects the handle to the actuator pin, bypassing the faulty inlet actuator. When the handle is rotated, the cable transmits the disconnection force directly to the actuator pin, enabling reliable emergency disconnection even when the original actuator malfunctions.
Solution Approach 2:
The patent extracts the emergency disconnection function from the malfunctioning inlet actuator by creating a separate, independent manual disconnection system. The handle and cable form a standalone mechanism that can operate the actuator pin directly, separating the emergency disconnection path from the normal automated actuation path.
2Reliability
If a manual disconnection mechanism is added to ensure emergency disconnection capability, then emergency reliability is improved, but the device complexity increases
Solution Approach 1:
The patent segments the disconnection function into distinct components: a handle for user operation, a cable for force transmission, and a direct connection point on the actuator pin. This segmentation allows each component to perform its specific function simply and reliably, avoiding the need for a complex integrated mechanism.
Solution Approach 2:
Instead of adding complexity to the actuator itself to enable manual override, the patent inverts the approach by adding a simple manual operation interface (handle) that acts upon the existing actuator pin through the cable. This reverses the control direction from actuator-to-pin to handle-to-pin, simplifying the overall system architecture.
3Ease of operation
If the handle is designed to rotate and return automatically, then ease of operation is improved, but the device complexity increases due to the plate spring mechanism
Solution Approach 1:
The patent implements self-service by using a plate spring to automatically return the handle to its original position after the user releases it. The elastic restoring force of the plate spring provides automatic reset functionality without requiring additional actuators, motors, or control systems, maintaining simplicity while improving ease of operation.
Solution Approach 2:
The patent utilizes the elastic parameter of the plate spring to achieve automatic handle return. By selecting appropriate spring characteristics, the handle naturally returns to its initial position after rotation, transforming the manual operation into a self-resetting mechanism with minimal added 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
Enables easy and automatic disconnection of the outlet from the inlet in emergency situations, ensuring safety and preventing unauthorized use or theft by allowing users to manually disconnect the charging interface.
Implementation Method 1
the handle returns to the original position by an elastic restoring force when an external force is released after the rotation operation thereof
Data Source
AI summary
An apparatus for emergency disconnection of a battery charge inlet of an electric vehicle may include a case; a handle mounted in the case, and rotatable by partially exposing through a groove formed at one side of the case; and an emergency disconnection cable having one side connected to the handle, and having the other side connected to an emergency disconnection lever provided in an inlet actuator mounted on the inlet for charging an electric vehicle.