EV Charging Plug Overload Protection Mechanism
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Solution Overview
Problem
Existing charging apparatuses for electric vehicles lack effective protection against mechanical overload, which can lead to damage and exposure of voltage-carrying elements during charging, especially when the vehicle moves relative to the charging station.
Innovation Solution
The charging apparatus incorporates an adjusting facility with overload protection mechanisms, including a robotic arm with a desired separation site and a magnetic attachment, as well as a plug-in connection that separates and isolates the charging cable to prevent uncontrolled breakaway and exposure of current-carrying elements when a predetermined mechanical load is exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the adjusting facility is made rigid and strongly connected to both base element and plug element, then the mechanical strength and stability are improved, but the device becomes vulnerable to damage when mechanical overload occurs due to vehicle movement
Solution Approach 1:
The adjusting facility is divided into separable components: the lifting arm that can be detached from the base element, and the plug element that can be separated from the charging cable. This segmentation allows the system to maintain strength during normal operation while enabling controlled separation under overload conditions to prevent damage.
Solution Approach 2:
The lifting arm is pre-configured with a separation mechanism that automatically activates when mechanical overload occurs. This preliminary design ensures that before damage can occur to voltage-carrying elements, the system has already prepared the capability to separate components under excessive load conditions.
2Ease of operation
If the plug element is allowed to move freely with the vehicle during charging, then the ease of operation is improved, but the mechanical load on the adjusting facility increases and may cause damage
Solution Approach 1:
The system transitions from a static rigid connection to a dynamic controllable connection. The lifting arm can be automatically retracted or separated when vehicle movement exceeds predetermined thresholds, allowing the system to adapt its mechanical coupling state based on operational conditions.
Solution Approach 2:
The adjusting facility incorporates sensors or mechanisms that detect mechanical load conditions and vehicle movement. This feedback enables the system to monitor the mechanical state and automatically trigger separation when load exceeds safe limits, preventing damage while allowing normal operation.
3Productivity
If the electrical connection is maintained continuously between base element and plug element, then the charging efficiency is improved, but the risk of voltage-carrying element exposure increases when mechanical damage occurs
Solution Approach 1:
The electrical connection is extracted into a separable charging cable system. The charging cable can be disconnected from the plug element when mechanical overload occurs, removing the electrical connection before voltage-carrying elements can be exposed or damaged. This separates the electrical function from the mechanical structure.
Solution Approach 2:
The system incorporates protective measures before damage can occur: the separable charging cable and controlled separation mechanism prevent electrical exposure by removing the electrical connection in advance when mechanical stress exceeds safe thresholds.
4Reliability
If the adjusting facility is designed with separable components for overload protection, then the protection against damage is improved, but the device complexity increases
Solution Approach 1:
The adjusting facility is segmented into modular components (lifting arm, plug element, charging cable) that can independently separate. This segmentation provides overload protection while keeping each individual component relatively simple in design.
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
This solution ensures safe and reliable charging by mechanically and electrically separating the plug element from the base element before damage occurs, preventing exposure of voltage-carrying components and allowing for controlled reconnection, thus protecting the charging apparatus and ensuring safe operation.
Implementation Method 1
the magnetic attachment, as well as a plug-in connection that separates and isolates the charging cable to prevent uncontrolled breakaway and exposure of current-carrying elements when a predetermined mechanical load is exceeded
Data Source
AI summary
A charging apparatus for charging a battery of an electrically operable vehicle includes a plug element, a base element, and adjusting facility. The plug element is connectable to a corresponding, vehicle-side plug element of the motor vehicle and via which electrical energy is transferrable to the motor vehicle so as to charge the battery. The base element is connected to a current source and provides electrical energy from the current source for the plug element. Via the adjusting facility the plug element is movable relative to the base element in order to connect the plug element to the vehicle-side plug element, and via which an electrical connection is provided between the base element and the plug element. The adjusting facility has an overload protection via which the base element is electrically separated from the plug element in the event of a predetermined mechanical maximal load being exceeded.