EV Charging Locking Mechanism with Spring Energy Storage
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Solution Overview
Problem
Existing plug locking mechanisms for electric vehicle charging stations fail to ensure safe operation during power outages and do not guarantee correct plug insertion, leading to potential damage and safety risks.
Innovation Solution
A device with a locking element that uses a spring-loaded lever and sensors to ensure correct plug insertion and provides auxiliary energy for unlocking during power failures, preventing the locking element from being moved into the locking position unless the plug is correctly seated, and allowing the plug to be unlocked using secondary energy when primary energy is unavailable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electric drive is used to move the locking element from release position to locking position, then the plug can be securely locked in the socket, but the plug cannot be unlocked if the electrical supply energy drops
Solution Approach 1:
A spring element is pre-loaded during the locking operation to store mechanical energy. This preliminary action ensures that when electrical power is available, the spring is charged, and when power is lost, the stored energy automatically enables unlocking without requiring additional electrical energy.
Solution Approach 2:
The spring-loaded mechanism provides self-service by using the energy stored during normal operation to automatically unlock the plug during power failures. The system serves itself by converting the locking action's stored energy into unlocking capability, eliminating the need for external power during emergency unlocking.
2Productivity
If the locking element is moved without verifying correct plug insertion, then the locking operation can proceed quickly, but damage may occur to the locking element and/or plug and/or socket
Solution Approach 1:
A sensor detects the position of the locking element and generates an end position signal that provides feedback to the control unit. This feedback mechanism ensures that the locking operation only completes successfully when the plug is correctly inserted and the locking element reaches its final position, preventing damage while maintaining efficient operation.
Solution Approach 2:
The system dynamically adjusts the locking process based on real-time sensor feedback. The control unit monitors the end position signal and only permits the charging process to start when correct insertion is confirmed, creating a dynamic safety check that prevents damage without significantly delaying the locking operation.
3Productivity
If the charging process starts without confirming correct plug insertion, then the charging can begin immediately, but safety cannot be guaranteed
Solution Approach 1:
The control unit receives an end position signal from the sensor that confirms correct plug insertion. This feedback loop ensures that the charging process is only permitted to start when the system verifies that the plug is properly seated and locked, eliminating safety risks while minimizing delay through automated verification.
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
Ensures safe operation by preventing charging if the plug is not correctly inserted and allows the plug to be unlocked during power failures, ensuring the vehicle can be safely uncoupled from the charging station.
Implementation Method 1
A lever which is acted upon by a spring force, is mounted about a pivot point of the same and is brought into the locking position by the spring force
Data Source
Figure 1~2
Figure 3~8
AI summary
The invention relates to a device for locking a plug in a socket, which is integrated into a charging station or an electrically powered vehicle, wherein electrical energy can be provided for the electrically powered vehicle by means of the charging station, with a movable locking element which, in a locking position, engages in a recess of the plug for connecting it to the socket, and with a locking element associated with the locking element which can be actuated by means of a drive unit, wherein the locking element can be locked in the recess of the plug in a locking position and wherein the locking element can be released in a release position for removing the plug.wherein at least one end position determination unit is assigned to the detent element and/or the locking element for generating an end position signal such that the detent position of the detent element and/or the locking position of the locking element can be detected by means of the end position signal.