Emergency Unlocking Controller for EV Charging Plug
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Solution Overview
Problem
Current emergency unlocking methods for electric vehicle charging stations require large, costly capacitors and wear-prone relay contacts, with inefficient energy conversion and redundant hardware components, leading to unreliable and costly operations.
Innovation Solution
A self-sufficient emergency unlocking controller with a step-up converter supplies power to the electric-motor drive unit, reducing capacitor size and cost, eliminating relay contacts, and integrating control functions to manage energy and safety monitoring through communication interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large capacity capacitors (20 mF to 50 mF) are used to store sufficient energy for emergency unlocking, then reliable emergency unlocking is achieved, but the cost and size of the capacitor increase significantly
Solution Approach 1:
The patent replaces the traditional capacitor-based energy storage system with a fuel cell-based energy generation system. The fuel cell converts chemical energy directly into electrical energy through electrochemical reactions, eliminating the need for large capacitors while providing sufficient energy for emergency unlocking operations.
Solution Approach 2:
The patent changes the energy storage parameter from electrical energy (capacitor) to chemical energy (fuel cell). This fundamental parameter change allows the system to provide the required energy for emergency unlocking without the size and cost penalties of large capacitors, as the fuel cell generates electricity on-demand through electrochemical conversion.
2Reliability
If relay contacts are used to connect the capacitor to the electric motor during emergency operation, then emergency unlocking can be initiated, but the relay contacts are subject to wear from high short-circuit currents and have limited service life
Solution Approach 1:
The patent replaces the mechanical relay contact system with an electronic control system using transistors or MOSFETs as switching elements. These solid-state components have no mechanical wear, eliminating the service life limitation of relay contacts while maintaining the ability to connect and disconnect the fuel cell from the motor during emergency operations.
Solution Approach 2:
The patent introduces an intermediate electronic switching stage (transistor/MOSFET) between the control signal and the high-current fuel cell connection. This intermediary component handles the high currents without mechanical contact wear, extending system reliability while maintaining emergency operation capability.
3Adaptability or versatility
If two separate hardware motor controllers are used (one for normal operation, one for emergency unlocking), then both operational modes are supported, but the device complexity and hardware redundancy increase
Solution Approach 1:
The patent designs a single motor controller that can operate in both normal charging mode and emergency unlocking mode. The controller includes dual H-bridge circuits that can be configured for different operational requirements, eliminating the need for separate hardware controllers while maintaining full functionality for both operating scenarios.
Solution Approach 2:
The patent merges the normal operation controller and emergency unlocking controller into a single integrated control unit. This unified controller manages both operational modes through software control and configurable hardware circuits, reducing component count and system complexity while maintaining adaptability to different operational requirements.
4Speed
If high current is used to activate the motor quickly for emergency unlocking, then rapid response is achieved, but the relay contacts experience increased wear and reduced service life
Solution Approach 1:
The patent replaces mechanical relay contacts with solid-state electronic switches (transistors/MOSFETs) that can handle high currents without mechanical wear. This substitution maintains the rapid response capability needed for emergency unlocking while eliminating the service life degradation caused by high current mechanical contact wear.
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 solution enables reliable, low-wear, and efficient emergency unlocking with reduced hardware needs, precise current control, and enhanced safety monitoring, utilizing stored energy efficiently and eliminating fault-prone components.
Implementation Method 1
a step-up converter for supplying power to the electric-motor drive unit, the input voltage of the step-up converter being stepped up to the nominal voltage of the electric motor
Implementation Method 2
the electric motor which activates the locking mechanism must be switched on for several milliseconds (emergency operation). For this purpose, an electric capacitor in normal operation is charged till the nominal motor voltage has been reached
Data Source
AI summary
A method and a circuit arrangement for unlocking a charging plug in an emergency designed for a charging station for charging an electric energy storage of an electric vehicle, having a locking mechanism activated by an electric-motor drive unit. An emergency unlocking controller is a self-sufficient functional block in conjunction with a step-up converter for supplying the electric-motor drive unit with power, the input voltage of the step-up converter stepped up to the nominal voltage of the electric motor. A microcontroller controls and monitors the electric-motor drive unit and the step-up converter and for communicating with a superordinate locking controller generally disposed in the charging station. The step-up converter allows nearly the entire electric energy stored in the storage capacitor connected upstream of the step-up converter to be supplied to the electric-motor drive unit, whereby the motor can be operated at its required nominal voltage.