Locking EV Charging Connector for Loading Dock Departure Prevention
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Solution Overview
Problem
Loading dock accidents involving electric-powered vehicles occur when they depart prematurely during cargo transfer, posing safety risks to forklift operators and personnel, as existing safety systems are inadequate to prevent such incidents.
Innovation Solution
A loading dock-integrated electric vehicle charging system that includes a controller and a lockable latching mechanism for the charging connector, which transitions between functional and locked-out states to prevent the vehicle from departing until cargo transfer is complete, integrating with loading dock safety equipment to ensure safe operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charging connector is made lockable to prevent vehicle departure, then loading dock safety is improved, but the complexity of the charging system increases
Solution Approach 1:
The patent combines the charging connector locking mechanism with the charging station controller, integrating the safety function into the existing charging system rather than adding a separate locking device. The controller manages both charging operations and connector locking, reducing overall system complexity while maintaining safety.
Solution Approach 2:
The patent introduces a safety control device as an intermediary between the charging station and loading dock safety equipment. This mediator coordinates the locking mechanism with dock safety systems, managing the complexity through centralized control rather than distributed components.
2Reliability
If the charging connector is locked during cargo transfer, then personnel safety is improved, but the ease of operation deteriorates
Solution Approach 1:
The charging connector locking mechanism is designed to be dynamic rather than static. The connector can be locked during cargo transfer and automatically unlocked when charging is complete, allowing the system to adapt its state based on operational requirements without manual intervention.
Solution Approach 2:
The system performs automatic locking and unlocking operations without requiring manual intervention from operators. The controller monitors charging status and automatically engages or disengages the locking mechanism, eliminating the need for operators to manually lock or unlock connectors.
3Object-affected harmful factors
If the system integrates with loading dock safety equipment, then accident prevention is improved, but the device complexity increases
Solution Approach 1:
The safety control device is designed with multi-functionality, serving both as a charging station controller and a loading dock safety system integrator. It manages connector locking, charging operations, and coordination with dock safety equipment through a single unified controller, reducing the need for separate specialized devices.
Solution Approach 2:
The system implements feedback mechanisms where the safety control device continuously monitors the state of both the charging connector and loading dock safety equipment. This feedback loop allows automatic coordination and adjustment of safety measures based on real-time system conditions, simplifying integration through intelligent control rather than hardwired connections.
Data Source
AI summary
A loading dock safety system integrated with an electric vehicle charging station is disclosed. The system employs an electric vehicle charging station for charging electric vehicles and a safety control device for monitoring and controlling the loading dock safety equipment. The electric vehicle charging station has a charging connector with an electronically controlled latching mechanism to secure the charging connector to the charging port of the electric vehicle. During the process of loading and unloading cargo from the electric vehicle, the charging connector is locked to the charging port, which, in turn, prevents the EV from departing from the loading dock until the transfer of cargo is complete.