EVSE Coupler Locking Logic for Broken Latch Detection
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Solution Overview
Problem
Existing vehicle charging systems lack effective mechanisms to ensure secure and reliable locking of the charger coupler to the vehicle port, leading to potential inadvertent decoupling and associated risks such as arcing and thermal events.
Innovation Solution
A coupler locking system with an electromechanical mechanism and control logic that uses a lock plate or cam to actively monitor the coupler's position, ensuring secure locking by applying additional force if necessary, and disabling charging if the coupler is not properly locked.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple coupler latch mechanism is used, then the device complexity is reduced, but the reliability of secure locking is compromised
Solution Approach 1:
The patent implements a feedback mechanism where a sensor detects the position of the locking element and provides this information to a controller. The controller monitors whether the locking element has reached the locked position and can detect if the latch is broken or malfunctioning. This closed-loop feedback system enhances reliability by continuously verifying the locked state without requiring a fundamentally more complex mechanical structure.
Solution Approach 2:
The patent replaces purely mechanical locking verification with an electromechanical system. Instead of relying solely on mechanical interlocks and physical keys, the system uses sensors to detect locking element position and controllers to manage the charging enable/disable state. This substitution allows for more reliable detection of locked states and broken latches while keeping the overall system complexity manageable through electronic control.
2Reliability
If additional force is applied to ensure proper locking, then the secure locking is improved, but the device complexity increases due to actuator requirements
Solution Approach 1:
The patent applies preliminary action by having the locking element engage the latch before charging is enabled. The system proactively verifies the locked state through sensor detection and controller verification before allowing charging to commence. This preliminary verification ensures reliable latch engagement without requiring complex continuous monitoring mechanisms throughout the charging process.
Solution Approach 2:
The locking system incorporates self-service characteristics where the actuator automatically positions the locking element and the sensor automatically detects whether locking occurred. The controller then autonomously determines whether to enable or disable charging based on this detection, without requiring manual intervention or complex external monitoring systems.
3Object-affected harmful factors
If the charging system disables charging when latch position is uncertain, then safety is improved, but the productivity of charging is reduced
Solution Approach 1:
The patent applies preliminary anti-action by preventing charging from starting if the latch is not properly locked. The sensor detects the locking element position before charging begins, and the controller disables charging if the latch is broken or malfunctioning. This preliminary safety check prevents harmful decoupling events before they can occur, while only affecting productivity when actual latch problems are detected.
Solution Approach 2:
The system accepts that the latch is a consumable component that may wear out or break over time. Rather than designing for indefinite latch life, the system includes detection capabilities to identify when the latch has failed and disables charging accordingly. This approach prioritizes safety over continuous operation, accepting that the latch may need periodic replacement while keeping the overall system cost-effective.
Data Source
AI summary
Presented are charger coupler locking systems with control logic for managing vehicle charging, methods for making/using such systems, and vehicles equipped with such systems. A method of controlling charging of a vehicle includes a vehicle controller receiving a signal indicating a charger coupler of a vehicle charging system is inserted into a charger port of the vehicle and, when received, responsively commanding an actuator device of a coupler locking system to move a locking element against a latching element of the charger coupler. The controller then receives sensor data from a position sensing device indicative of a travel position of the locking element; from this sensor data, the controller determines if the locking element's travel position is displaced from a predefined lock position at which the locking element contacts the latching element. If so, the controller responsively commands the vehicle's battery charging system to disable charging of the battery assembly.