Single Sensor Linear Actuator for EV Charging Safety Lock
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Solution Overview
Problem
The Fast Charge function for electric vehicles poses safety risks due to high currents during charging, as the Fast Charge connector can be accidentally removed, leading to exposure or arcing.
Innovation Solution
A safety lock device with a movable locking pin, actuator, sensor, and control unit that determines the locking status by measuring the distance the locking pin has traveled, preventing the connector from being removed during charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a Fast Charge connector is used to enable high voltage and current charging, then charging speed is improved, but safety risks increase due to potential accidental removal during charging
Solution Approach 1:
The safety lock device is activated before charging begins, with the locking pin extending into the locked position to prevent connector removal. The sensor detects the locked status in advance, and the control system prepares the locking mechanism, ensuring safety is established before the harmful high current charging process starts.
Solution Approach 2:
The locking pin acts as an intermediary mechanical element between the connector and receptacle. It physically blocks the connector from being removed by inserting into a slot or opening, serving as a mediator that prevents direct contact between the operator and the high current charging interface.
2Measurement precision
If a safety lock device with multiple sensors is used to accurately detect locking status, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The single sensor performs multiple functions: it detects both the locked and unlocked positions of the locking pin, and provides feedback to the control system for status determination. This multi-functional sensor replaces what would otherwise require multiple specialized sensors, maintaining measurement precision while reducing device complexity.
Solution Approach 2:
The sensor detects changes in physical parameters (such as position, distance, or optical properties) of the locking pin to determine locking status. By monitoring parameter changes rather than using multiple sensors, the system achieves accurate detection with simpler hardware configuration.
Data Source
AI summary
A safety lock device for locking a charging connector in a charging receptacle of an electric vehicle is provided. The safety lock device includes a locking pin movable between a first position and a second position, an actuator configured to drive the locking pin between the first position and second position, a sensor configured to measure information used in determining a distance the actuator has driven the locking pin and a control unit electrically connected to the sensor and configured to receive the measured information from the sensor and determine the status of the safety lock based on the measured information received from the sensor. The charging connector and charging receptacle may be part of a Fast Charge coupler.