EV Connector Integrating Abnormality Detection and Mechanical Power Cut-Off
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Solution Overview
Problem
Conventional charging cables for electric vehicles lack protection against short-circuit and leakage abnormalities between the connector and control box, hindering safe power supply and storage usability.
Innovation Solution
A connector design with a contact unit, power cut-off unit, abnormality detection, and transmission mechanisms integrated into the connector main body at the cable end, allowing for real-time detection and mechanical disconnection of power in case of abnormalities, enhancing safety and usability by eliminating the need for a mid-cable control box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a control box is provided in the middle of the electric cable to detect abnormalities, then abnormality detection function is improved, but cable storage usability deteriorates
Solution Approach 1:
The patent extracts the control box from the middle of the electric cable and relocates it to the end of the cable. This extraction resolves the contradiction by removing the obstacle that hampered cable storage while preserving the abnormality detection function through the relocated control box and integrated connector design.
2Reliability
If a control box is provided in the middle of the electric cable to detect abnormalities, then protection against short-circuit and leakage is improved, but device complexity increases
Solution Approach 1:
The patent merges the control box with the connector at the end of the cable, integrating multiple functions (abnormality detection, power cut-off, and connection) into a single unified component. This merging reduces device complexity by eliminating the separate mid-cable control box while maintaining protection functions through the integrated design.
Solution Approach 2:
The integrated connector serves multiple functions simultaneously: it provides abnormality detection through the abnormality detection unit, power cut-off through the power cut-off unit, and electrical connection through the contact unit. This multi-functionality maintains protection capabilities while reducing overall system complexity.
3Extent of automation
If conventional control apparatus is used to stop power supply, then power supply control is improved, but protection against electric power from electric storage device is worsened
Solution Approach 1:
The patent inverts the conventional unidirectional power control approach by implementing bidirectional protection. The power cut-off unit can open the electric conductor unit to disconnect power flow in either direction - from the electric storage device to the connector or from the connector to the electric storage device. This inversion provides comprehensive protection against abnormalities regardless of power flow direction.
Data Source
AI summary
A connector main body of a connector accommodates a contact unit, a power cut-off unit that has an electric conductor unit, and open and close a power feeding path between an electrically driven vehicle and an electric power apparatus by bringing into contact or opening electric conductor unit, and an abnormality detection unit that detects an abnormality that occurs on power feeding path, or receives an abnormality signal from outside, an abnormality transmission unit that, when abnormality detection unit detects abnormality or receives abnormality signal, mechanically opens electric conductor unit, and a handle that mechanically brings into contact or opens electric conductor unit in a state in which abnormality detection unit does not detect abnormality and does not receive abnormality signal. Abnormality detection unit detects at least one of a short-circuit current and an overload current that occur on power feeding path as abnormality.