Automated EV Charging Plug Ejection Mechanism

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Solution Overview

Problem

Current vehicle charging systems require drivers to exit the vehicle and manually unplug the charging plug, which is inefficient, and existing solutions for cord storage lack smart actuation and control over charger ejection.

Innovation Solution

An automated ejection and retraction mechanism for the charging plug and cord, utilizing a spring-loaded connector with a release lever actuated by a control unit, and a self-retracting reel assembly in the charging station that automatically retracts the power cord upon predetermined conditions or user command.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual unplugging is required, then the driver can control the charging process, but the driver must exit the vehicle and manually unplug the charger

Engineering Contradiction:

Improveease of unpluggingVSAvoidtime to unplug

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system performs the unplugging operation automatically without requiring driver intervention. The ejection mechanism is activated by the vehicle's control unit when startup conditions are met, causing the charging plug to be automatically ejected from the connector, thereby eliminating the need for the driver to manually unplug the charger

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual mechanical action of the driver exiting the vehicle, grasping the plug, and pulling it out is replaced by an automated ejection mechanism. This mechanism uses a spring-loaded system actuated by a motor or other drive mechanism to mechanically eject the plug from the connector housing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If automated ejection mechanism is added, then unplugging is automated, but device complexity increases

Engineering Contradiction:

Improveautomation of ejectionVSAvoidcomplexity of ejection mechanism

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The ejection mechanism is integrated into the existing connector assembly, which already serves multiple functions (electrical connection, mechanical retention, alignment). The connector housing incorporates both the electrical contacts and the ejection mechanism, allowing a single component to perform both charging and automated ejection functions

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The ejection mechanism is nested within the connector housing structure. The spring-loaded ejection system is contained within the existing connector assembly, with the plug nested within the housing that contains the ejection mechanism, creating a compact integrated structure

Inventive Principle:

Principle #7Nested doll (Nesting)

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 plug ejection without the driver needing to exit the vehicle, enhancing convenience and efficiency by automating the charging process, allowing for faster start-up and safer cord management.

Implementation Method 1

a spring configured to apply a force to a charging plug when inserted in a connector

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9365116B2Vehicle recharging station and support devices

Publication Date: 2016.06.14 FORD GLOBAL TECH LLC

AI summary

The present disclosure relates to an electric vehicle, including: a connector configured to receive a charging plug; and an ejection mechanism positioned with respect to the connecter, configured to eject the plug under predetermined conditions.