Charging Inlet Actuator Brush Mechanism Against Lever Arm Sticking
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Solution Overview
Problem
Inlet actuators used in electric mobility charging systems can become inoperable due to debris causing the lever arm to stick, leading to issues with locking or releasing the charging plug.
Innovation Solution
An anti-sticking device is introduced, which includes a housing, a drive shaft, a lever arm, and a brush unit. The brush unit is seated on the lever arm and contacts the housing to remove debris generated between them, preventing sticking and ensuring proper operation of the inlet actuator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the inlet actuator components are closely fitted to ensure compact structure, then the device size is reduced, but debris can easily cause sticking between components
Solution Approach 1:
A brush unit is introduced as an intermediary component between the lever arm and housing. The brush unit contacts both surfaces and removes debris that accumulates in the narrow gap, preventing sticking while allowing the components to remain closely fitted for compact structure
Solution Approach 2:
The brush unit is designed to be automatically driven by the rotation of the lever arm itself. As the lever arm rotates during normal operation, it drives the brush unit to rotate and clean the housing surface, eliminating the need for a separate power source or actuation mechanism
2Ease of operation
If the lever arm is positioned outside the housing for easy operation, then ease of operation is improved, but debris accumulation between the lever arm and housing causes sticking
Solution Approach 1:
The brush unit serves as a mediator between the externally positioned lever arm and the housing. It continuously removes debris from the interface between these two components, ensuring smooth rotation while maintaining the lever arm's external position for ease of operation
Solution Approach 2:
The brush unit performs preliminary cleaning action by removing debris before it can accumulate to problematic levels. The brush is positioned to contact the housing surface in advance of where debris would cause sticking, preventing the sticking issue before it occurs
3Reliability
If the brush unit is added to prevent sticking, then reliability is improved, but device complexity increases
Solution Approach 1:
The brush unit serves multiple functions: it removes debris from the housing surface, prevents sticking between components, and is automatically driven by the lever arm rotation itself. This multi-functionality justifies the addition of the component while minimizing the increase in overall system complexity
Solution Approach 2:
The brush unit is self-actuating through the lever arm's own rotation. The lever arm's rotational motion directly drives the brush unit without requiring additional motors, sensors, or control systems, thereby limiting the increase in device complexity while achieving the anti-sticking function
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
The anti-sticking device effectively prevents the lever arm from sticking due to debris, ensuring the inlet actuator remains operational and allowing for smooth locking and releasing of the charging plug.
Implementation Method 1
a brush unit seated on the lever arm and configured to remove debris generated between the housing and the lever arm while being in contact with the housing during operation of the lever arm
Data Source
AI summary
An embodiment device includes a housing, an actuator mounted in the housing, the actuator configured to be operated in response to a connection state of a charging plug, a drive shaft configured to be rotated in conjunction with an operation of the actuator, a lever arm rotatably provided outside the housing and connected to the drive shaft to be rotated together with the drive shaft, and a brush unit seated on the lever arm and configured to remove debris between the housing and the lever arm while being in contact with the housing during operation of the lever arm.