Description:TECHNICAL FIELD
[0001] The present disclosure relates to automotive technology. In particular, the present disclosure relates to an apparatus and a method for accessing a lock set beyond an ON state to disable an electrical connection before removing a charging connector to mitigate a risk of electric damage to vehicular components.

BACKGROUND
[0002] In electric vehicles, a locking mechanism of a charging handle or charging connector is operated by a solenoid to engage the charging connector with a charging inlet of a vehicle and is regulated by an Electronic Control Unit (ECU). An existing locking mechanism uses the ECU to receive signals from a lockset to indicate whether the lockset is in an ON state or an OFF state and transmits the response signals to the solenoid to lock and unlock the charging connector.
[0003] However, the existing locking mechanism is too expensive as the specific push and pull of a plunger on the vehicle inlet is achieved through the solenoid for vehicle architecture because the solenoid requires a coil that is to be energized to create a push-pull mechanism controlled by magnets and coils. Additionally, circuit requirements of the existing locking mechanism are significant, including an H-bridge to reverse a current flow for up and down movement (e.g., a vertical movement) of the plunger and a signal harness to monitor a position of the plunger, making the existing locking mechanism too expensive with respect to benefits.
[0004] Therefore, there is a need to address the above-mentioned drawbacks, along with any other shortcomings, or at the very least, to provide a viable alternative locking and unlocking mechanism of the charging connector.

OBJECTS OF THE PRESENT DISCLOSURE
[0005] A general object of the present disclosure relates to an efficient and a reliable locking and unlocking mechanism of a charging connector that obviates the above-mentioned limitations of existing locking mechanisms.
[0006] An object of the present disclosure is to provide an apparatus and method for accessing a lock set beyond an ON state to disable an electrical connection before removing a charging connector to mitigate a risk of electric damage to vehicular components.
[0007] Another object of the present disclosure is to provide an apparatus and method for triggering a plunger to move between a first position and a second position based on actuation inputs received by a lock set, thereby effectively managing a charging connector and eliminating a need for a solenoid.

SUMMARY
[0008] Aspects of the disclosure relate to automotive technology. In particular, the present disclosure provides an apparatus and a method for accessing a lock set beyond ON state to disable an electrical connection before removing a charging connector to mitigate a risk of electric damage to vehicular components.
[0009] In an aspect, the present disclosure relates to an apparatus for managing a charging connector in a vehicle. The apparatus includes a lock set, a charging inlet, and a string member. The charging inlet includes a plunger, wherein the plunger is configured to move between a first position and a second position. The string member is linked between the lock set and the plunger of the charging inlet, wherein the string member triggers the plunger to move from the first position to the second position based on one or more actuation inputs received by the lock set for managing the charging connector.
[0010] In an embodiment, the lock set may be configured with at least one of: an ON state, an OFF state, a seat unlock state, a handle unlock/lock state, and a charging connector unlock state.
[0011] In an embodiment, the charging connector unlock state may be configured beyond the ON state, where a control unit may disconnect power supply between a battery and a motor to turn OFF the vehicle, when an access element provides the one or more actuation inputs beyond the ON state in the lock set.
[0012] In an embodiment, the first position of the plunger may represent a lock position, and the second position of the plunger may represent an unlock position.
[0013] In an embodiment, the string member may pull the plunger from the first position to the second position for unlocking the charging connector when the access element provides the one or more actuation inputs beyond the ON state in the lock set.
[0014] In an embodiment, the lock set may be configured with a spring-loaded mechanism that enables the access element to automatically return to a position of the ON state after unlocking the charging connector.
[0015] In an embodiment, the string member may release the plunger to move from the first position to the second position in response to returning of the access element to the position of the ON state.
[0016] In an embodiment, the plunger may be configured with one or more springs, where each of the one or more springs may be compressed and decompressed corresponding to the movement of the plunger between the first position and the second position.
[0017] In an embodiment, each of the springs may be compressed when the plunger is moved from the first position to the second position, and where each of the one or more springs may be decompressed when the plunger is moved from the second position to the first position.
[0018] In an embodiment, each of the one or more springs may be decompressed when the plunger is moved from the first position to the second position, and where each of the one or more springs may be compressed when the plunger is moved from the second position to the first position.
[0019] In an embodiment, the plunger may include a first end and a second end, and where the first end may be linked to the string member, and the second end may protrude outwards from the charging inlet when the plunger is in the first position.
[0020] In an embodiment, the charging connector may include a predefined gap corresponding to a shape of the second end of the plunger.
[0021] In an embodiment, when the plunger is in the first position, the charging connector may be inserted towards the charging inlet to move the plunger to the second position such that the second end of the plunger may be affixed to the predefined gap causing the charging connector to lock with the charging inlet.
[0022] In an embodiment, when the plunger is moved from the second position to the first position in response to the one or more actuation inputs, the second end of the plunger may be detached from the predefined gap causing the charging connector to unlock with the charging inlet.
[0023] In an embodiment, when the access element triggers the lock set to the ON state and the charging connector is locked with the charging inlet, an electrical connection between the charging connector and the charging inlet may be disabled.
[0024] In an embodiment, when the access element triggers the lock set to one of: the OFF state, the seat unlock state, or the handle unlock/lock state and the charging connector is locked with the charging inlet, the electrical connection between the charging connector and the charging inlet may be enabled.
[0025] In another aspect, the present disclosure relates to a method for managing a charging connector in a vehicle. The method includes configuring a plunger in a charging inlet associated with an apparatus and linking the plunger and a lock set associated with the apparatus via a string member for triggering the plunger to move from a first position to a second position based on one or more actuation inputs received by the lock set for managing the charging connector.
[0026] In an embodiment, the method may include pulling the plunger from the first position to the second position for unlocking the charging connector when an access element provides the one or more actuation inputs beyond the ON state in the lock set and disconnecting power supply between a battery and a motor to turn OFF the vehicle, when the access element provides the one or more actuation inputs beyond the ON state in the lock set.
[0027] In an embodiment, the method may include releasing the plunger to move from the second position to the first position corresponding to the returning of the access element to the position of the ON state.
[0028] In an embodiment, the method may include compressing and decompressing one or more springs corresponding to the movement of the plunger between the first position and the second position.
[0029] In an embodiment, the method may include compressing the one or more springs when the plunger is moved from the first position to the second position and decompressing the one or more springs when the plunger is moved from the second position to the first position.
[0030] In an embodiment, the method may include decompressing the one or more springs when the plunger is moved from the first position to the second position and compressing the one or more springs when the plunger is moved from the second position to the first position.
[0031] In an embodiment, the method may include affixing a second end of the plunger to a predefined gap of the charging connector causing the charging connector to lock with the charging inlet when the charging connector is inserted towards the charging inlet.
[0032] In an embodiment, the method may include detaching the second end of the plunger from the predefined gap causing the charging connector to unlock with the charging inlet when the plunger is moved from the second position to the first position in response to the one or more actuation inputs.
[0033] In an embodiment, the method may include disabling an electrical connection between the charging connector and the charging inlet when an access element triggers the lock set to the ON state and the charging connector is locked with the charging inlet.
[0034] In an embodiment, the method may include enabling the electrical connection between the charging connector and the charging inlet when the access element triggers the lock set to any one of: the OFF state, the seat unlock state, or the handle unlock/lock state and the charging connector is locked with the charging inlet.
[0035] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0037] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with embodiments of the present disclosure.
[0038] FIGs. 2A-2D illustrate schematic views of a charging inlet locking mechanism, in accordance with prior arts.
[0039] FIG. 3 illustrates a schematic view of a lock set, in accordance with embodiments of the present disclosure.
[0040] FIGs. 4A-4D illustrate schematic views of a plunger movement in response to actuation inputs, in accordance with embodiments of the present disclosure.
[0041] FIGs. 5A-5B illustrate schematic views of a locking and unlocking mechanism of a charging connector using a string member linked between the lock set and the plunger, in accordance with embodiments of the present disclosure.
[0042] FIG. 6 illustrates a flow chart of a method for managing the charging connector in a vehicle, in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[0043] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosures as defined by the appended claims.
[0044] For the purpose of understanding of the principles of the present disclosure, reference will now be made to the various embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present disclosure is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the present disclosure as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present disclosure relates.
[0045] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are explanatory of the present disclosure and are not intended to be restrictive thereof.
[0046] Whether or not a certain feature or element was limited to being used only once, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language including, but not limited to, “there needs to be one or more” or “one or more elements is required.”
[0047] Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements of the present disclosure. Some embodiments have been described for the purpose of explaining one or more of the potential ways in which the specific features and/or elements of the proposed disclosure fulfil the requirements of uniqueness, utility, and non-obviousness.
[0048] Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment,” “additional embodiment” or other variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or in the context of more than one embodiment, or in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
[0049] Any particular and all details set forth herein are used in the context of some embodiments and therefore should not necessarily be taken as limiting factors to the proposed disclosure.
[0050] The terms “comprise,” “comprising,” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by “comprises... a” does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.
[0051] Embodiments of the present disclosure will be described below in detail with reference to the accompanying drawings.
[0052] For the sake of clarity, the first digit of a reference numeral of each component of the present disclosure is indicative of the Figure number, in which the corresponding component is shown. For example, reference numerals starting with digit “1” are shown at least in FIG. 1. Similarly, reference numerals starting with digit “2” are shown at least in FIG. 2.
[0053] An Electric Vehicle (EV) or a battery powered vehicle including, and not limited to two-wheelers such as scooters, mopeds, motorbikes/motorcycles; three-wheelers such as auto-rickshaws, four-wheelers such as cars and other Light Commercial Vehicles (LCVs) and Heavy Commercial Vehicles (HCVs) primarily work on the principle of driving an electric motor using the power from the batteries provided in the EV. Furthermore, the electric vehicle may have at least one wheel which is electrically powered to traverse such a vehicle. The term ‘wheel’ may be referred to any ground-engaging member which allows traversal of the electric vehicle over a path. The types of EVs include Battery Electric Vehicle (BEV), Hybrid Electric Vehicle (HEV), and Range Extended Electric Vehicle. However, the subsequent paragraphs pertain to the different elements of a Battery Electric Vehicle (BEV).
[0054] FIG. 1 illustrates a schematic view of an Electric Vehicle (EV), in accordance with embodiments of the present disclosure.
[0055] In construction, an EV (10) typically comprises a battery or a battery pack (12) enclosed within a battery casing and includes a Battery Management System (BMS), an on-board charger (14), a Motor Controller Unit (MCU), an electric motor (16), and an electric transmission system (18). The primary function of the above-mentioned elements is detailed in the subsequent paragraphs. The battery of the EV (10) (also known as Electric Vehicle Battery (EVB) or traction battery) is re-chargeable in nature and is the primary source of energy required for the operation of the EV (10), wherein the battery (12) is typically charged using the electric current taken from the grid through a charging infrastructure (20). The battery (12) may be charged using Alternating Current (AC) or Direct Current (DC), wherein in case of AC input, the on-board charger (14) converts the AC signal to DC signal after which the DC signal is transmitted to the battery (12) via the BMS. However, in case of DC charging, the on-board charger (14) is bypassed, and the current is transmitted directly to the battery (12) via the BMS.
[0056] The battery (12) is made up of a plurality of cells which are grouped into a plurality of modules in a manner in which the temperature difference between the cells does not exceed 5 degrees Celsius. The terms “battery”, “cell”, and “battery cell” may be used interchangeably and may refer to any of a variety of different rechargeable cell compositions and configurations including, but not limited to, lithium-ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium-ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel-zinc, silver zinc, or other battery type/configuration. The term “battery pack” as used herein may be referred to multiple individual batteries enclosed within a single structure or multi-piece structure. The individual batteries may be electrically interconnected to achieve a desired voltage and capacity for a desired application. The Battery Management System (BMS) is an electronic system whose primary function is to ensure that the battery (12) is operating safely and efficiently. The BMS continuously monitors different parameters of the battery (12) such as temperature, voltage, current, and so on, and communicates these parameters to the Electronic Control Unit (ECU) and the Motor Controller Unit (MCU) in the EV (10) using a plurality of protocols including and not limited to a Controller Area Network (CAN) bus protocol which facilitates the communication between the ECU/MCU and other peripheral elements of the EV (10) without the requirement of a host computer.
[0057] The MCU primarily controls/regulates the operation of the electric motor (16) based on the signal transmitted from the vehicle battery (12), wherein the primary functions of the MCU include starting of the electric motor (16), stopping the electric motor (16), controlling the speed of the electric motor (16), enabling the vehicle (10) to move in the reverse direction and protect the electric motor (16) from premature wear and tear. The primary function of the electric motor (16) is to convert electrical energy into mechanical energy, wherein the converted mechanical energy is subsequently transferred to the transmission system of the EV (10) to facilitate movement of the EV (10). Additionally, the electric motor (16) also acts as a generator during regenerative braking (i.e., kinetic energy generated during vehicle braking/deceleration is converted into potential energy and stored in the battery of the EV). The types of motors generally employed in EVs (10) include, but are not limited to a DC series motor, a Brushless DC motor (also known as BLDC motors), a Permanent Magnet Synchronous Motor (PMSM), Three Phase AC Induction Motors, and Switched Reluctance Motors (SRM).
[0058] The transmission system (18) of the EV (10) facilitates the transfer of the generated mechanical energy by the electric motor (16) to the wheels (22a, 22b) of the EV (10). Generally, the transmission systems (18) used in EVs (10) include single speed transmission system and multi-speed (i.e., two-speed) transmission system, wherein the single speed transmission system comprises a single gear pair whereby the EV (10) is maintained at a constant speed. However, the multi-speed/two-speed transmission system comprises a compound planetary gear system with a double pinion planetary gear set and a single pinion planetary gear set thereby resulting in two different gear ratios which facilitates higher torque and vehicle speed.
[0059] In one embodiment, all data pertaining to the EV (10) and/or charging infrastructure (20) are collected and processed using a remote server (known as cloud) (24), wherein the processed data is indicated to the rider/driver of the EV (10) through a display unit present in the dashboard (26) of the EV (10). In an embodiment, the display unit may be an interactive display unit. In another embodiment, the display unit may be a non-interactive display unit.
[0060] FIGs. 2A-2D illustrate schematic views (200A, 200B, 200C, 200D) of a charging inlet locking mechanism, in accordance with prior arts.
[0061] Referring to FIG. 2A and 2B, in an existing vehicle inlet locking mechanism, a horizontal plunger (202) pushes inward and transfers a pushing force to a vertical plunger (204), effectively locking a charging connector. Conversely, when the horizontal plunger (202) is retracted, the vertical plunger (204) also pulls back, thus releasing the lock from the charging connector. Referring to FIG. 2C, the horizontal plunger (202) is configured with a shaft (202A) that is designed to convert horizontal motion into vertical motion through a general gear mechanism. Similarly, referring to FIG. 2D, when the shaft (202A) is retracted, the vertical plunger (204) also pulls back. Additionally, the existing vehicle inlet locking mechanism includes a spring-loaded, one-way wedge-shaped plunger that maintains a default locked state. Upon insertion of the charging connector, the wedge-shaped plunger engages the lock, preventing removal until an Electric Control Unit (ECU) of a vehicle transmits a signal to a solenoid to release the lock. However, the existing vehicle inlet locking mechanism depends on the solenoid that creates electrical malfunctions. Such dependency may lead to situations where the existing vehicle inlet locking mechanism either fails to secure the charging connector properly or becomes unable to release, potentially causing inconvenience or delays in a charging process.
[0062] Unlike the existing charging inlet locking mechanism, which often relies on electromechanical systems, the present disclosure may replace the electromechanical systems entirely with a mechanical module (e.g., an apparatus). This may enhance security of a portable charger (e.g., the charging connector), ensuring the portable charger remains safely attached and theft-proof while charging the vehicle in any location. The mechanical module may only use a pull-by-wire mechanism (e.g., a string member) to carry out an unlocking operation without using the solenoids.
[0063] Embodiments of the present disclosure relate to automotive technology. In particular, the present disclosure provides an apparatus and a method for accessing a lock set beyond an ON state to disable an electrical connection before removing a charging connector to mitigate a risk of electric damage to vehicular components. Various embodiments of the present disclosure will be explained in detail with respect to FIGs. 3-6.
[0064] FIG. 3 illustrates a schematic view (300) of a lock set (302), in accordance with embodiments of the present disclosure.
[0065] Referring to FIG. 3, in a vehicle, the lock set (302) may be configured with such as, but not limited to an ON state, an OFF state, a seat unlock state, a handle unlock/lock state, a charging connector unlock state, and the like. In an embodiment, the charging connector unlocks state may be configured beyond the ON state. In an embodiment, when a key (e.g., an access element) is inserted into the lock set (302) and provides actuation inputs, a control unit of the vehicle may detect a position of the access element. When the access element provides the actuation inputs to the ON state or beyond the ON state (e.g., the charging connector unlock state) in the lock set (302), the control unit detects that the position of the access element is in the ON state or beyond the ON state. Once the position of the access element is detected in the ON state or beyond the ON state, the control unit may disconnect power supply between vehicular components. For example, the control unit disconnects the power supply between a battery and a motor to turn OFF the vehicle, when the control unit detects that the position of the access element is in the ON state or beyond the ON state.
[0066] FIGs. 4A-4D illustrate schematic views (400A, 400B, 400C, 400D) of a plunger (406) movement in response to the actuation inputs, in accordance with embodiments of the present disclosure.
[0067] Referring to FIG. 4A, a charging inlet (402) may include the plunger (406) configured to move between a lock position (e.g., a first position) and an unlock position (e.g., a second position) along with springs (408). In an embodiment, a string member (404) may be linked between the lock set (302) and a first end (406A) of the plunger (406). The string member (404) may trigger the plunger (406) to move from the first position to the second position based on the actuation inputs received by the lock set (302) for managing the charging connector. Simultaneously, the springs (408) may be compressed and decompressed corresponding to the movement of the plunger (406) between the first position and the second position plunger (406). Referring to FIG. 4A, in normal stage, the plunger (406) may be in the first position and the springs (408) may be in a compressed state. In an embodiment, a second end (406B) of the plunger (406) may protrude outwards from an outer housing of the charging inlet (402).
[0068] Referring to FIG. 4B, the charging connector (not shown in figures) may include a predefined gap corresponding to a shape of the second end (406B) of the plunger (406). In an embodiment, when the plunger (406) is in the first position and the springs (408) are in the compressed state, the charging connector may be inserted towards the charging inlet (402) to move the plunger (406) from the first position to the second position. Simultaneously, the springs (408) may be decompressed when the plunger (406) is moved from the first position to the second position. Once the plunger (406) is moved to the second position, the charging connector may be completely inserted into the charging inlet (402). Once the charging connector is completely inserted into the charging inlet (402), the plunger (406) may be moved from the second position to the first position to affix the second end (406B) within the predefined gap. Simultaneously, the springs (408) may be compressed when the plunger (406) is moved from the second position to the first position. Once the second end (406B) is affixed within the predefined gap, the charging connector may be locked with the charging inlet (402).
[0069] In an embodiment, once the charging connector is locked with the charging inlet (402), the control unit may detect that the charging connector is locked with the charging inlet (402) and may enable the power supply or an electrical connection (e.g., between the charging connector and the charging inlet (402) to charge the battery. At this stage, when a user triggers the lock set (302) to the ON state, the control unit may disable the electrical connection between the charging connector and the charging inlet (402). In an embodiment, when the access element triggers the lock set (302) to one of the OFF state, the seat unlock state, or the handle unlock/lock state and the charging connector is locked with the charging inlet (402), the control unit may enable the electrical connection between the charging connector and the charging inlet (402).
[0070] In an embodiment, when the user provides the actuation inputs by triggering the access element towards any one of the ON state, the OFF state, the seat unlock state, or the handle unlock/lock state associated with the lock set (302), the plunger (406) may be in the lock position (e.g., the first position). Similarly, when the user provides the actuation inputs beyond the ON state (e.g., the charging connector unlock state), the string member (404) may pull the plunger (406) from the first position to the second position. Once the plunger (406) moves from the first position to the second position, the charging inlet (402) may unlock the charging connector by detaching the second end (406B) of the plunger (406) from the predefined gap, thereby unlocking the charging connector from the charging inlet (402). Once the charging connector is unlocked, the user may remove the charging connector from the charging inlet (402).
[0071] In exemplary embodiments, a locking process for the vehicle inlet is a straightforward operation and secure engagement. To lock the charging connector into the charging inlet (402), the user may push the charging connector from the left side of the plunger (406). The plunger (406) at the charging inlet (402), designed with a wedge-shaped front, facilitates this by allowing the charging connector to slide. Once the connector is fully inserted, the springs (408) within the plunger (406) may be decompressed from the natural state and then compressed, thereby securing the charging connector into place.
[0072] In exemplary embodiments, unlocking the charging connector and the charging inlet (402) may be user-friendly and secure. The pull-by-wire mechanism may be connected from the lock set (302) to the plunger (406). When the user intent to remove the charging connector, the user may activate the pull-by-wire mechanism via the lock set (302). This action may retract the plunger (406) and the springs (408) to unlock the charging connector and the charging inlet (402). With the springs (408) and the plunger (406) retracted, the charging connector is free to be removed. This design may ensure that the locking and unlocking sequence is not only simple to execute but also inherently secure. The natural tension of the springs (408) may hold the charging connector in place firmly until the user deliberately initiates the unlocking process, preventing inadvertent disconnection or tampering.
[0073] In an embodiment, referring to FIG. 4C, in the normal stage, the plunger (406) may be in the first position and the springs (408) may be in a decompressed state. In an embodiment, the second end (406B) of the plunger (406) may protrude outwards from the outer housing of the charging inlet (402). Referring to FIG. 4D, when the plunger (406) is in the first position and the springs (408) are in the decompressed state, the charging connector may be inserted towards the charging inlet (402) to move the plunger (406) from the first position to the second position. Simultaneously, the springs (408) may be compressed when the plunger (406) is moved from the first position to the second position. Once the plunger (406) is moved to the second position, the charging connector may be completely inserted into the charging inlet (402). Once the charging connector is completely inserted into the charging inlet (402), the plunger (406) may be moved from the second position to the first position to affix the second end (406B) within the predefined gap. Simultaneously, the springs (408) may be decompressed when the plunger (406) is moved from the second position to the first position. Once the second end (406B) is affixed within the predefined gap, the charging connector may be locked with the charging inlet (402).
[0074] In exemplary embodiments, the charging connector may be inserted from the left side of the charging inlet (402). The wedge-shaped plunger (406) of the second end (406B) may facilitate easy entry of the charging connector. Once fully inserted, the springs (408) may be compressed to accommodate the charging connector and then decompressed back into a resting state, effectively locking the charging connector in place. For unlocking, the pull-by-wire mechanism may be integrated with the lock set (302). When the user operates the lock set (302), the pull-by-wire mechanism may pull the plunger (406) and the attached spring’s inwards, unlocking the charging inlet (402) and the charging connector. This retraction of the springs (408) and the plunger (406) may allow for the subsequent removal of the charging connector.
[0075] In exemplary embodiments, a mechanical module (e.g., an apparatus) may be designed for fast charging and may prevent unauthorized unlocking of the charging handle or charging connector during the charging process. The mechanical module may be equipped with a spring-loaded (e.g., the springs (408)), one-way wedge-shaped plunger (406), maintaining a default locked state. As soon as the charging connector is inserted, the charging connector may secure automatically, and prevent detaching from the charging inlet (402) until the charging connector is manually unlocked from the lockset (302). The flow of Direct Current (DC) current (e.g., the power supply), whether for fast charging or slow charging, is only permitted after a locking mechanism (e.g., the charging connector is locked with the plunger (406)) is engaged and a communication handshake is successfully completed. Once the spring-loaded wedge-shaped plunger (406) locks the charging connector, the control unit may trigger the communication handshake for enabling a transfer of the DC current. A charging process may be initiated only when the vehicle is turned OFF. In an embodiment, the user may simply insert the charging connector into the charging inlet (402), which then automatically locks in the plunger (406). This action establishes communication, allowing the user to lock the vehicle and leave the vehicle to charge, and thereby ensuring effectiveness of the locking mechanism.
[0076] In exemplary embodiments, in order to comply with safety standards and ensure proper operation during a charging session, the design of a charging system (e.g., the apparatus) may incorporate critical features that prevent the disengagement of the charging connector under hazardous conditions. During the charging session, the user may not be able to remove the charging connector while charging is active or when voltage is present at the charging connector, as such an action may result in dangerous arcing. Repeated instances of attempted disengagement under these conditions may lead to significant damage to both the charging inlet (402) and the charging connector.
[0077] Furthermore, for EVs, a mandatory safety feature requires that the charging process may only occur when an EV (10) is in the off state. This requirement is met without the need for electrical controls by designing the lockset (302) and associated states. The lockset (302) may be configured such that when the vehicle is in the OFF state, indicated by the access element being latched on the OFF side, the charging connector may remain locked in place. In this state, even if charging is underway, the charging connector may not be disengaged.
[0078] In exemplary embodiments, to disengage the charging connector, the user must first turn the access element towards the ON state, which interrupts the charging session, and then rotate the access element further (e.g., beyond the ON state) to unlock the charging connector. This mechanical interlock mechanism (e.g., charging connector locked with the charging inlet (402)) may ensure that the charging connector may only be released safely when the vehicle is not charging, thus preventing any potential electrical hazards.
[0079] In exemplary embodiments, the EV (10) charging mechanism may be designed with various states to ensure safe and secure charging, each with specific functions to prevent improper disengagement of the charging connector. In the OFF state, which is the default state for initiating charging, the user may insert the charging connector into the vehicle inlet. The plunger (406) along with the spring tension, automatically secures the charging connector upon insertion. This engagement may trigger a Controller Area Network (CAN) communication through pins, starting the charging process. The lockset may be inactive in this state and does not interfere with the locking mechanism of the charging connector, ensuring the charging connector may not be disengaged while charging is in progress.
[0080] In exemplary embodiments, if the vehicle was previously charging, turning the access element to the ON state may stop the charging process. The plunger (406) may remain in a locked position, keeping the charging connector securely in place. If the user then decides to initiate charging again, the user may simply rotate the access element back to the OFF state, and the vehicle may follow a programmed charging procedure.
[0081] In exemplary embodiments, the plunger (406) unlock state may be enabled when there is a need to disengage the charging connector. By rotating the access element further away from the ON position, the lockset may activate a pull wire mechanism (e.g., the string member (404)). This mechanism may interact with the charging connector, retract the plunger (406), and release the charging connector, allowing for removal. In the seat unlock state and handle lock/unlock state, the apparatus may ensure the charging connector and the plunger (406) are maintained in a locked state, and prevent being unlocked inadvertently. This state is critical for maintaining the safety and security of the charging system, preventing accidental or unauthorized disconnection of the charging connector.
[0082] In exemplary embodiments, the present disclosure may be designed to ensure that the EV's charging connector is only engaged or disengaged during appropriate times, utilizing the position of the access element to control the state of the charging mechanism. This may eliminate the risk of electrical arcing and damage to the charging system by ensuring that the charging connector may only be released when it is safe to do so.
[0083] FIGs. 5A-5B illustrate schematic views (500A, 500B) of a locking and unlocking mechanism of the charging connector using the string member (404) linked between the lock set (302) and the plunger (406), in accordance with embodiments of the present disclosure.
[0084] Referring to FIGs. 5A, the lock set (302) may be configured with a spring-loaded mechanism. For example, when the lock set (302) is at any one of the ON state, the OFF state, the seat unlock state, and the handle unlock/lock state, the string member (404) may stabilize the plunger (406) at the first position. Similarly, when the user triggers the lock set (302) beyond the ON state (e.g., the charging connector unlock state) using the access element, the string member (404) may release the plunger (406) to move from the first position to the second position. This movement may facilitate by the access element, which automatically returns to the position of the ON state using the spring-loaded mechanism as illustrated in FIG. 5B. This ensures that before removing the charging connector, the electrical connection may be disabled to protect against unnecessary damage to the vehicular components such as the battery, a charging port, and the like. Further, an electric shock or sparks caused by unplanned disconnection may be minimized.
[0085] FIG. 6 illustrates a flow chart of a method (600) for managing the charging connector in the vehicle, in accordance with embodiments of the present disclosure.
[0086] Referring to FIG. 6, at (602), the method (600) may include configuring the plunger (406) in the charging inlet (402) associated with the apparatus.
[0087] At (604), the method (600) may include linking the plunger (406) and the lock set (302) associated with the apparatus via the string member (404). In an embodiment, the method (600) may include pulling the plunger (406) from the first position to the second position for unlocking the charging connector when the access element provides the actuation inputs beyond the ON state in the lock set (302) and disconnecting the power supply between the battery and the motor to turn OFF the vehicle, when the access element provides the actuation inputs beyond the ON state in the lock set (302). In an embodiment, the method (600) may include releasing the plunger (406) to move from the second position to the first position corresponding to the returning of the access element to the position of the ON state.
[0088] At (606), the method (600) may include triggering the plunger (406) to move from the first position to the second position based on the one or more actuation inputs received by the lock set (302) for managing the charging connector. In an embodiment, the method (600) may include compressing and decompressing the springs (408) corresponding to the movement of the plunger (406) between the first position and the second position. In an embodiment, the method (600) may include compressing the springs (408) when the plunger (406) is moved from the first position to the second position and decompressing the springs (408) when the plunger (406) is moved from the second position to the first position. In an embodiment, the method (600) may include decompressing the springs (408) when the plunger (406) is moved from the first position to the second position and compressing the springs (408) when the plunger (406) is moved from the second position to the first position.
[0089] In an exemplary embodiment, the method (600) may include affixing the second end (406B) of the plunger (406) to the predefined gap of the charging connector causing the charging connector to lock with the charging inlet (402) when the charging connector is inserted towards the charging inlet (402). In an exemplary embodiment, the method (600) may include detaching the second end (406B) of the plunger (406) from the predefined gap causing the charging connector to unlock with the charging inlet (402) when the plunger (406) is moved from the second position to the first position in response to the actuation inputs.
[0090] In an embodiment, the method (600) may include disabling an electrical connection between the charging connector and the charging inlet (402) when an access element triggers the lock set (302) to the ON state and the charging connector is locked with the charging inlet (402). In an embodiment, the method (600) may include enabling the electrical connection between the charging connector and the charging inlet (402) when the access element triggers the lock set (302) to any one of: the OFF state, the seat unlock state, or the handle unlock/lock state and the charging connector is locked with the charging inlet (402).
[0091] In this application, unless specifically stated otherwise, the use of the singular includes the plural and the use of “or” means “and/or.” Furthermore, use of the terms “including” or “having” is not limiting. Any range described herein will be understood to include the endpoints and all values between the endpoints. Features of the disclosed embodiments may be combined, rearranged, omitted, etc., within the scope of the disclosure to produce additional embodiments. Furthermore, certain features may sometimes be used to advantage without a corresponding use of other features.
[0092] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the disclosure is determined by the claims that follow. The disclosure is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE PRESENT DISCLOSURE
[0093] The present disclosure provides an apparatus and a method that ensures a charging connector remains securely locked during a charging process, reducing the risk of theft or tampering.
[0094] The present disclosure provides an apparatus and a method for preventing accidental disconnections that lead to electrical shorts or damage to a charging port of a vehicle.
[0095] The present disclosure provides an apparatus and a method for minimizing an electric shock or sparks caused by unplanned disconnection.
[0096] The present disclosure provides a cheapest way to lock and unlock a charging connector without using a solenoid.
, Claims:1. An apparatus for managing a charging connector in a vehicle, comprising:
a lock set (302);
a charging inlet (402) comprising a plunger (406), wherein the plunger (406) is configured to move between a first position and a second position; and
a string member (404) linked between the lock set (302) and the plunger (406) of the charging inlet (402), wherein the string member (404) triggers the plunger (406) to move from the first position to the second position based on one or more actuation inputs received by the lock set (302) for managing the charging connector.
2. The apparatus as claimed in claim 1, wherein the lock set (302) is configured with at least one of: an ON state, an OFF state, a seat unlock state, a handle unlock/lock state, and a charging connector unlock state.
3. The apparatus as claimed in claim 2, wherein the charging connector unlock state is configured beyond the ON state, and wherein a control unit disconnects power supply between a battery and a motor to turn OFF the vehicle, when an access element provides the one or more actuation inputs beyond the ON state in the lock set (302).
4. The apparatus as claimed in claim 1, wherein the first position of the plunger (406) represents a lock position, and the second position of the plunger (406) represents an unlock position.
5. The apparatus as claimed in claim 3, wherein the string member (404) pulls the plunger (406) from the first position to the second position for unlocking the charging connector when the access element provides the one or more actuation inputs beyond the ON state in the lock set (302).
6. The apparatus as claimed in claim 5, wherein the lock set (302) is configured with a spring-loaded mechanism that enables the access element to automatically return to a position of the ON state after unlocking the charging connector.
7. The apparatus as claimed in claim 6, wherein the string member (404) releases the plunger (406) to move from the first position to the second position in response to returning of the access element to the position of the ON state.
8. The apparatus as claimed in claim 1, wherein the plunger (406) is configured with one or more springs (408), and wherein each of the one or more springs (408) are compressed and decompressed corresponding to the movement of the plunger (406) between the first position and the second position.
9. The apparatus as claimed in claim 8, wherein each of the one or more springs (408) is compressed when the plunger (406) is moved from the first position to the second position, and wherein each of the one or more springs (408) is decompressed when the plunger (406) is moved from the second position to the first position.
10. The apparatus as claimed in claim 8, wherein each of the one or more springs (408) is decompressed when the plunger (406) is moved from the first position to the second position, and wherein each of the one or more springs (408) is compressed when the plunger (406) is moved from the second position to the first position.
11. The apparatus as claimed in claim 1, wherein the plunger (406) comprises a first end (406A) and a second end (406B), and wherein the first end (406A) is linked to the string member (404), and the second end (406B) protrudes outwards from the charging inlet (402) when the plunger (406) is in the first position.
12. The apparatus as claimed in claim 11, wherein the charging connector comprises a predefined gap corresponding to a shape of the second end (406B) of the plunger (406).
13. The apparatus as claimed in claim 12, wherein when the plunger (406) is in the first position, the charging connector is inserted towards the charging inlet (402) to move the plunger (406) to the second position such that the second end (406B) of the plunger (406) is affixed to the predefined gap causing the charging connector to lock with the charging inlet (402).
14. The apparatus as claimed in claim 12, wherein when the plunger (406) is moved from the second position to the first position in response to the one or more actuation inputs, the second end (406B) of the plunger (406) is detached from the predefined gap causing the charging connector to unlock with the charging inlet (402).
15. The apparatus as claimed in claim 2, wherein when the access element triggers the lock set (302) to the ON state and the charging connector is locked with the charging inlet (402), an electrical connection between the charging connector and the charging inlet (402) is disabled.
16. The apparatus as claimed in claim 15, wherein when the access element triggers the lock set (302) to one of: the OFF state, the seat unlock state, or the handle unlock/lock state and the charging connector is locked with the charging inlet (402), the electrical connection between the charging connector and the charging inlet (402) is enabled.
17. A method (600) for managing a charging connector in a vehicle, comprising:
configuring (602) a plunger (406) in a charging inlet (402) associated with an apparatus;
linking (604) the plunger (406) and a lock set (302) associated with the apparatus via a string member (404); and
triggering (606) the plunger (406) to move from a first position to a second position based on one or more actuation inputs received by the lock set (302) for managing the charging connector.
18. The method (600) as claimed in claim 17, comprising:
pulling the plunger (406) from the first position to the second position for unlocking the charging connector when an access element provides the one or more actuation inputs beyond the ON state in the lock set (302); and
disconnecting power supply between a battery and a motor to turn OFF the vehicle, when the access element provides the one or more actuation inputs beyond the ON state in the lock set (302).
19. The method (600) as claimed in claim 17, comprising:
releasing the plunger (406) to move from the second position to the first position corresponding to the returning of the access element to the position of the ON state.
20. The method (600) as claimed in claim 17, comprising:
compressing and decompressing one or more springs (408) corresponding to the movement of the plunger (406) between the first position and the second position.
21. The method (600) as claimed in claim 20, comprising:
compressing the one or more springs (408) when the plunger (406) is moved from the first position to the second position and decompressing the one or more springs (408) when the plunger (406) is moved from the second position to the first position.
22. The method (600) as claimed in claim 20, comprising:
decompressing the one or more springs (408) when the plunger (406) is moved from the first position to the second position and compressing the one or more springs (408) when the plunger (406) is moved from the second position to the first position.
23. The method (600) as claimed in claim 20, comprising:
affixing a second end (406B) of the plunger (406) to a predefined gap of the charging connector causing the charging connector to lock with the charging inlet (402) when the charging connector is inserted towards the charging inlet (402).
24. The method (600) as claimed in claim 23, comprising:
detaching the second end (406B) of the plunger (406) from the predefined gap causing the charging connector to unlock with the charging inlet (402) when the plunger (406) is moved from the second position to the first position in response to the one or more actuation inputs.
25. The method (600) as claimed in claim 17, comprising:
disabling an electrical connection between the charging connector and the charging inlet (402) when an access element triggers the lock set (302) to the ON state and the charging connector is locked with the charging inlet (402).

26. The method (600) as claimed in claim 25, comprising:
enabling the electrical connection between the charging connector and the charging inlet (402) when the access element triggers the lock set (302) to any one of: the OFF state, the seat unlock state, or the handle unlock/lock state and the charging connector is locked with the charging inlet (402).