EV Charge Lock Manual Override Mechanism
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Solution Overview
Problem
Motor-driven lock devices for charge cables in electric vehicles fail to unlock when the actuator malfunctions, preventing the removal of the charge cable from the power port.
Innovation Solution
A lock device with a transmission member that can be manually moved to an unlock position using a forcible unlocking mechanism, allowing for manual unlocking even if the lock motor fails, and a holding unit to keep the unlocking wire in place during normal operations, reducing the load on the lock motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a motor-driven lock device is used to automatically lock and unlock the charge cable, then the ease of operation is improved, but the reliability deteriorates because the lock cannot be unlocked if the actuator fails
Solution Approach 1:
An unlocking wire is introduced as an intermediary mechanical element that directly connects to the transmission member. When the actuator fails, this wire can be manually pulled to move the transmission member and unlock the lock pin, providing a backup unlocking path that bypasses the failed actuator system.
Solution Approach 2:
The system changes its operational mode from purely motor-driven to a hybrid mechanical system. By incorporating the manual unlocking wire that directly actuates the transmission member, the system gains the ability to switch between automated operation (normal mode) and manual operation (failure mode), thereby maintaining reliability under different conditions.
2Reliability
If a forcible unlocking mechanism is added to enable manual unlocking, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The essential unlocking function is extracted from the complex actuator system and embodied in a simple mechanical wire that directly moves the transmission member. This extracted mechanism consists of minimal components (wire, holding unit) that perform the critical backup unlocking function without adding significant complexity to the overall system.
Solution Approach 2:
The transmission member is designed with dual functionality: it can be moved by the actuator during normal automated operation, and it can also be moved by the manual unlocking wire when the actuator fails. This multi-functionality allows a single component to serve both automated and manual unlocking purposes, reducing the need for separate dedicated mechanisms.
3Reliability
If the transmission member is freely movable to enable manual unlocking, then the reliability is improved, but the ease of operation deteriorates because the unlocking wire cannot be held in place during normal operations
Solution Approach 1:
The holding unit provides a dynamic constraint on the transmission member. During normal automated operation, the holding unit constrains the transmission member to prevent unintended movement. During manual unlocking, the constraint is released or overridden, allowing the transmission member to move freely when the wire is pulled. This dynamic behavior resolves the contradiction between freedom of movement and positional stability.
Solution Approach 2:
The holding unit pre-positiones and secures the transmission member in its normal operational state before any unlocking action occurs. This preliminary positioning ensures that the transmission member remains stable during automated locking/unlocking operations, while still allowing manual intervention when needed.
Data Source
AI summary
A lock device includes a lock member moved between a lock position, at which the lock member restricts removal of a locking subject from a power port, and an unlock position, at which the lock member permits removal of the locking subject from the power port. A transmission member is moved between a first position, at which the transmission member fixes the lock member at the lock position, and a second position, at which the transmission member permits movement of the lock member to the unlock position. A auxiliary unlocking mechanism includes a movable forcible unlocking member, which manually moves the transmission member to the second position, and a holding unit, which holds the forcible unlocking member while permitting such movement. The auxiliary unlocking mechanism may be used should there be failure of the main unlocking mechanism.