EV Charging Lock Pin Sensor Protection
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Solution Overview
Problem
Existing locking devices for electric vehicle charging plugs are vulnerable to external influences such as weather conditions and mechanical stresses, which can compromise contact security and reliability, leading to potential safety issues and incomplete charging connections.
Innovation Solution
A locking device with a movable locking pin driven by an electric motor, featuring a conductor track structure with resilient contact tabs protected by a protective wall, which absorbs mechanical stresses and shields against environmental factors, ensuring secure and reliable electrical contact throughout the charging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the locking pin is made movable to enable locking and unlocking operations, then the ease of operation is improved, but the reliability deteriorates due to wear and contact degradation over time
Solution Approach 1:
The locking pin is divided into two functional parts: a movable portion that enables locking/unlocking operations and a fixed sensor portion that maintains reliable electrical contact. The sensor element is arranged on the locking pin but remains stationary relative to the housing, while the locking pin itself moves to engage or disengage from the other plug connector half.
Solution Approach 2:
The sensor element is positioned in a different spatial dimension relative to the movable locking pin portion. The sensor element is arranged on the locking pin in such a way that it remains in a fixed position relative to the housing, while the locking pin moves in a direction that does not affect the sensor element's position, allowing operational movement without compromising contact reliability.
2Ease of operation
If the contact tabs are exposed to detect locking pin position, then the ease of operation is improved, but the reliability deteriorates due to plastic deformation under mechanical stress
Solution Approach 1:
Different parts of the locking pin have different mechanical properties. The sensor region with contact tabs is designed with higher mechanical stability and resistance to plastic deformation, while the locking portion maintains its movability. The protective wall provides localized reinforcement to the contact tab region without affecting the overall locking mechanism.
Solution Approach 2:
The protective wall is positioned beforehand to shield the contact tabs from mechanical stresses that could cause plastic deformation. This protective structure is in place before any damaging forces are applied, preventing deformation rather than correcting it after the fact.
3Ease of manufacture
If the contact tabs are exposed to the environment, then the ease of manufacture is improved, but the reliability deteriorates due to environmental influences
Solution Approach 1:
A protective wall structure is introduced to shield the contact tabs from environmental influences such as moisture, dust, and temperature extremes. This protective enclosure maintains the simplicity of the manufacturing process while significantly improving the reliability of the electrical contact by protecting it from environmental degradation.
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 protective wall design enhances contact security by preventing plastic deformation of contact tabs under mechanical stress and protecting against environmental influences, ensuring reliable and safe charging connections over the entire product cycle.
Implementation Method 1
a sensor element that is arranged on the locking pin and is in the form of a conductor track structure, it being possible to establish an electrical contact with the conductor track structure by means of resilient tabs
Implementation Method 2
a means for protecting the contact tabs at least in the region of the contact tabs... the protective wall design enhances contact security by preventing plastic deformation of contact tabs under mechanical stress
Data Source
AI summary
A locking device for a plug connector half, whereby the locking device is driven by an electric motor, for establishing an electrical connection to another plug connector half in order to charge an electric vehicle or a hybrid vehicle by plugging the other plug connector half into the plug connector half. The locking device comprises a movable locking pin for locking the other plug connector half that has been plugged into the plug connector half, and a sensor element that is arranged on the locking pin and is in the form of a conductor track structure, it being possible to establish an electrical contact with the conductor track structure by means of resilient contact tabs and to provide a means for protecting the contact tabs at least in the region of the contact tabs.