Modular Electric Vehicle Connector with Automated Locking and Verification
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Solution Overview
Problem
Existing electric vehicle connection systems lack safety and protection against accidental disconnection and unauthorized interference, particularly in public charging settings, where correct connection is not guaranteed and third-party interference is a concern.
Innovation Solution
A modular vehicle system with a separable connection between an electric vehicle's interface and a module, featuring a mechanical locking mechanism that ensures secure electrical and mechanical connection, preventing accidental disconnection and unauthorized access, using a locking system that can be manually or motorized, with a control unit for compatibility verification and PIN code entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a separable connection is used between vehicle and module, then ease of operation is improved, but reliability deteriorates due to risk of accidental disconnection
Solution Approach 1:
The connecting element is inserted into a receptacle, creating a nested structure where the plug fits inside the socket. This nesting provides natural mechanical guidance and retention, making the connection both easy to establish and difficult to accidentally disconnect, as the nested geometry prevents random separation while allowing intentional insertion.
Solution Approach 2:
The system performs preliminary verification of compatibility between vehicle and module before final connection is established. The control unit checks compatibility parameters prior to enabling full electrical connection, preventing incompatible connections from being made and ensuring reliability before operation begins.
2Reliability
If a mechanical locking mechanism is added to prevent accidental disconnection, then reliability is improved, but device complexity increases
Solution Approach 1:
The electrical connection and mechanical locking functions are merged into a single integrated connector assembly. The same receptacle and connecting element that establish electrical contact also provide mechanical retention through their geometric fit, eliminating the need for separate locking mechanisms and reducing overall system complexity while maintaining reliability.
3Reliability
If compatibility verification and locking control are implemented, then safety is improved, but ease of operation deteriorates due to additional steps
Solution Approach 1:
The control unit automatically performs compatibility verification and manages the locking mechanism without requiring manual intervention from the user. The system self-checks parameters, determines compatibility, and activates or deactivates locking automatically, maintaining ease of operation while ensuring safety through automated verification processes.
4Reliability
If protection against third-party interference is added, then reliability is improved, but device complexity increases
Solution Approach 1:
The mechanical connector and receptacle act as intermediaries that physically block access to electrical contacts when in the locked state. This intermediary structure prevents third-party interference by making the electrical connection inaccessible without first disengaging the mechanical lock, providing security through geometric design rather than complex electronic security systems.
Data Source
AI summary
A modular vehicle system is provided, comprising an electric vehicle, particularly a light electric vehicle, with at least a control device; an on-board power supply system for energy supply of an electric drive unit; an interface, connected to the on-board power supply system for connection of at least one module; and first locking means arranged at the interface. The modular vehicle system further comprising a module, with a module control, configured to communicate with the control device; an electric arrangement;a connecting element, separably connectable to the interface, for connection of the electric arrangement with the on-board power supply system; and second locking means arranged at the connecting element, formed for engagement with the first locking means, wherein at least one of the locking means is movable between a free position and a locking position. To increase the safety of operating the system, the module control is configured to send an identification signal to the control device upon connection of the connecting element to the interface; and the control device is configured to receive the identification signal, to compare the identification signal with at least one compatibility parameter, and in case that the identification signal corresponds to the compatibility parameter, to send an activation signal to at least one switch unit to connect the electric arrangement with the on-board power supply system.