Smart Charge Port Housing with Integrated Single Shaft Self-Locking Mechanism for Electric Vehicles

This research presents the development of an advanced Smart Charge Port Housing system for electric vehicles that incorporates intelligent actuation and an integrated single shaft self-locking mechanism. Conventional charge port systems rely on communication with the vehicle’s Body Control Module or Vehicle Control Unit, limiting functionality when the vehicle is in an ignition-off state. The proposed Charge Port Housing addresses this limitation through a microcontroller-based rotary actuator capable of autonomous decision-making, storing the last known position of the lid and executing operations independently of the vehicle’s electronic control architecture. The actuator operates via wired input signals and supports seamless communication over the Local Interconnect Network protocol during ignition-on state. A key innovation lies in the mechanical design: a single shaft self-locking mechanism that combines actuation and locking into a compact, unified assembly, eliminating the need for separate actuators or manual overrides. This allows for controlled locking and unlocking of the charging flap through precise rotational movement, improving security and preventing tampering. The mechanism supports smart functions such as auto-close with anti-pinch features and enhanced sealing using laser-welded joints to achieve Ingress Protection 69-level waterproofing, critical for adverse weather conditions. This integrated solution enhances user experience, vehicle security, and design flexibility while enabling reliable, intelligent operation across a wide range of use cases in both ignition-on and ignition-off scenarios. The technology offers significant potential for widespread application in future EV platforms requiring robust, self-contained, and intelligent charging interfaces.