Cable system for cable condition monitoring

Abstract

This disclosure relates to a cable system for monitoring cable condition, the use of such a cable system, a method for manufacturing such a cable system, a method for operating such a cable system, and computer program elements for operating such a cable system. The cable system includes a first adapter unit, a first sleeve unit, and a cable, wherein the cable includes at least a first end. The first adapter unit is connectable to an energy storage system, and the cable is configured to transmit power to the first adapter unit. The first sleeve unit is disposed between the first adapter unit and the first end of the cable and configured to provide protection between them. The first sleeve unit includes a first sensor unit configured to generate data based on strain applied to the first sleeve unit. The first sensor unit includes a first flexible electronic element that extends at least partially to the first end of the cable.

Description

Technical Field

[0001] This disclosure relates to a cable system for monitoring cable condition, the use of such a cable system, a method for manufacturing such a cable system, a method for operating such a cable system, and a computer program element for operating such a cable system. Background Technology

[0002] High-voltage (HV) cables are particularly used for transmitting electricity between energy storage systems and electrical energy sources. During use, HV cables can be affected by various factors, such as weather, airborne particulate matter and acid rain, cleaning / waxing / polishing products, and deposits, particles, and fumes that adhere to vehicle surfaces during use. Furthermore, HV cables can be damaged by misuse. For example, users may force the cable into less restrictive conditions than permitted, and / or flexible cables may bend beyond their elastic limits. Additionally, HV cables may age during storage. Cracks may appear in the cable's protective layer, and / or microcracks may be detected when there are minor changes in the cable's elasticity. Summary of the Invention

[0003] Therefore, it may be necessary to provide an improved cable system that monitors cable aging caused by external influences.

[0004] This problem is solved by the subject matter of this invention. It should be noted that several aspects of this disclosure described below are applicable to cable systems for cable condition monitoring, uses of such cable systems, methods of manufacturing such cable systems, methods of operating such cable systems, and computer program elements for operating such cable systems.

[0005] According to this disclosure, a cable system is proposed. The cable system includes a first adapter unit, a first sleeve unit, and a cable, wherein the cable includes at least a first end. The first adapter unit is connectable to an energy storage system, and the cable is configured to transmit power to the first adapter unit. The first sleeve unit is disposed between the first adapter unit and the first end of the cable and is configured to provide protection between them. The first sleeve unit includes a first sensor unit configured to generate data based on strain applied to the first sleeve unit. The first sensor unit includes a first flexible electronic element that extends at least partially to the first end of the cable.

[0006] The cable system according to this disclosure allows for precise monitoring of the aging of charging cables. Specifically, the cable can be bent at its junction with the adapter unit, which can be the interface between the cable and the energy storage system and / or electrical energy source to be charged. By positioning flexible electronics at the junction, which may be a critical part of the cable, user behavior and / or stresses acting on the cable can be reliably detected. In particular, external influences affecting the cable, such as mechanical forces, ultraviolet radiation (UV exposure), chemical exposure, temperature, moisture intrusion, acceleration, gravity, rodent attacks, etc., can be monitored in real time or at least at predetermined time intervals. Therefore, cable hazards and faults can be detected at an early stage, thereby maintaining the quality of the voltage (CCV) at the common collector.

[0007] The cable may include conductor elements surrounded and protected by insulating elements encased in a sheath. The cable may be connected to an energy storage system to be (re)charged. Specifically, a first end of the cable may be securely attached to a first adapter unit. The energy storage system may be a battery system that stores electrical energy and supplies it to machines and / or equipment to enable their operation. Therefore, the first adapter unit may be a connector, and it may include the shape of a plug or socket for electrical output. The first adapter unit may include, for example, an IEC 62196 Type 1 or Type 2 socket. The other end of the cable may also include the adapter unit, or it may be directly connected to a charging station or electrical source.

[0008] A first sleeve unit may be disposed at the junction between the first end of the cable and the first adapter unit. In other words, the first end of the cable and the first adapter unit may be joined together at the junction. The junction may be a critical part of the cable because users typically grip the first adapter unit forcefully, which may cause the junction to bend, twist, and / or stretch. The first sleeve unit may be securely attached to the first adapter unit and extend at least partially over the first end of the cable to provide protection for this vulnerable point. The first sleeve unit may be made of an elastic material such as rubber or plastic.

[0009] A first sensor unit, including a first flexible electronic element, can be integrated into the first sleeve unit and can monitor the condition of the cable. Specifically, the first flexible electronic element can detect strain applied to the first sleeve unit via the first adapter unit and / or the first end of the cable based on its elasticity. In other words, the first flexible electronic element can measure the stress applied to the first sleeve unit in real time through the morphological changes of the first flexible electronic element or the first sensor unit's expansion and contraction. The first sensor unit may include a first processing element that generates data based on the measurement results of the first flexible electronic element to determine whether the strain applied to the first sleeve unit is likely critical for further use of the cable.

[0010] In one example, the first flexible electronics element is configured to be expandable based on tensile strain applied to the first sleeve unit. The first flexible electronics element can measure the pressure distribution on the first sleeve unit and send the signal to a first processing element of the first sensor unit. The processing element can convert the signal into an intensity applied to the first sleeve unit. Among various external influences, tensile or compressive strain applied by bending, torsion, and / or stretching, which may be caused by human intervention, can be predicted based on user behavior to avoid further stress on the cable. Therefore, the user can prevent damage to the cable or the first sleeve unit by adjusting the tensile strain applied to the first sleeve unit and / or the cable. However, this application is not limited to human use, and the first flexible electronics element can also measure tensile or compressive strain applied by automated systems such as robotic arms.

[0011] The first flexible electronic component is not only flexible but also stretchable. The term "stretchable" can be understood as the first flexible electronic component being able to elongate when tension is applied, but return to its original size and shape when the tension is removed. For this purpose, the conductive sensing elements of the first flexible electronic component can be printed on a very thin but flexible and conformal substrate (layer), which allows the first flexible electronic component to stretch. Because the first flexible electronic component can extend from the first sleeve unit to the first end of the cable, it can accurately measure the tensile strain applied to a critical portion of the cable, namely the tensile strain at the junction between the cable and the first sleeve unit.

[0012] In one example, the first sensor unit is also configured to generate data based on the cable's integrity. In other words, the first flexible electronic component can be configured to generate data based on the cable's elasticity. The cable's insulation element can be made of rubber, silicone, or any polymeric material suitable for completely insulating the conductor element from the environment. The material of the insulation element can be the same as the material of the first sleeve unit. Alternatively, the material of the insulation element can be different from the material of the first sleeve unit and / or the material of the cable sheath.

[0013] However, insulation components can be subjected to external stresses such as tensile strain, weather, humidity, temperature, acceleration, gravity, ultraviolet radiation, chemical exposure, moisture intrusion, and rodent attacks, which can lead to material degradation and / or microcracks / fissures on the cable insulation components. This material aging can affect the elasticity of the insulation components. The first sensor unit can generate elasticity data at the junction between the first sleeve unit and the end of the cable based on the measurement results of the first flexible electronic component to reliably monitor the condition of the cable. Therefore, accurate measurement of cable aging / damage can be achieved.

[0014] In one example, the first sensor unit can be configured to generate data based on the cable's conductivity or resistance. Typically, the first sensor unit can be galvanically insulated from the cable current. However, induction-based measurements of electrical quantities can allow for the determination of the quality of the cable's conductor elements.

[0015] In one example, the first sensor unit is also configured to generate data based on the cable's temperature. The temperature of the first sleeve unit or cable can also affect their aging. Temperature measurements at the first sleeve unit or cable, preferably via the first flexible electronics, can be logged as cumulative temperature, which may impair the elasticity of the cable's insulation. The first sensor unit can generate temperature data at the junction between the first sleeve unit and the cable end to reliably monitor the cable's condition. Therefore, accurate aging measurements of the cable can be achieved.

[0016] In one example, the first sensor unit can be further configured to generate data based on the cable's humidity or ultraviolet radiation. The first flexible electronics can be configured to measure humidity at the first sleeve unit and / or the first end of the cable. Furthermore, the first flexible electronics can measure additional external influences that may affect cable aging, such as gravity, acceleration, balance, etc. Therefore, the first sensor unit can generate corresponding measurement data based on the measurements taken by the first flexible electronics at the junction between the first sleeve unit and the first end of the cable.

[0017] In one example, the first sensor unit can be configured to combine the generated data and predict user preferences and / or behaviors. This enables a dynamic measurement system, improving cable monitoring. Internet of Things (IoT) based approaches can further customize data acquisition based on customer preferences / usage patterns.

[0018] In one example, the cable system further includes a second adapter unit and a second sleeve unit. The second sleeve unit is disposed between the second adapter unit and a second end of the cable. The second sleeve unit includes a second sensor unit configured to generate data based on strain applied to the second sleeve unit. In other words, the cable system can be symmetrically formed such that the first adapter unit, the first sleeve unit, and the first sensor unit are arranged identically at the second end of the cable. The cable system can be a transportable cable system.

[0019] The second end of the cable can be securely attached to the second adapter unit, and the second sleeve can be configured to provide protection between the second adapter unit and the second end of the cable. Furthermore, the second sensor unit may include a second flexible electronic element that extends at least partially to the second end of the cable. The second flexible electronic element may also be configured to be expandable based on tensile strain applied to the second sleeve unit. The second sensor unit may be further configured to generate data based on external influences such as weather, gravity, acceleration, balance, ultraviolet radiation, chemical exposure, moisture intrusion, rodent attack, etc. Therefore, the second sensor unit can generate corresponding measurement data at the junction between the second sleeve unit and the second end of the cable to perform accurate aging measurements of the cable system.

[0020] If necessary, the number of sensors can be increased with the length of the cable or relative to the current or future application of the cable to be envisioned.

[0021] In one example, the second adapter unit is configured to be coupled to a charging station and / or an energy source. The transportable cable system can be configured to connect to a public or private charging station or to a power grid used to charge an energy storage system.

[0022] In one example, the sensor unit may include the ability to acquire data bidirectionally, allowing vehicles to operate on the power grid.

[0023] In one example, the cable system also includes a control unit. The control unit is configured to receive data generated by a first sensor unit and / or a second sensor unit, and to estimate the aging condition of the cable based on the received data. The control unit may include the capability for real-time calculations and provide a data repository. The first sensor unit and / or the second sensor unit may be configured to send generated measurement data to the control unit. Based on the measurement data, the control unit can rigorously analyze user behavior or preferences, which may allow calculations of the cable's aging level to prevent the use of damaged cables. Both the analyzed and calculated aging conditions can be stored in the control unit to estimate the cable's condition based on accumulated data.

[0024] In one example, the control unit is also configured to generate a warning signal based on the cable's aging condition if replacement is required. The warning signal can be in the form of a light, message, and / or beep. The control unit can send information about the cable's aging condition to the user interface device, allowing the user to monitor the cable's current condition. Additionally, the control unit can warn the user via the user interface device about critical conditions of the cable, enabling the user to repair or replace the cable. The user interface device can be, for example, a computer, mobile device, a display on a charging station, and / or a display in a vehicle being charged.

[0025] In one example, the control unit is configured to receive data from the first sensor unit and / or the second sensor unit via wireless communication. The control unit can be integrated into the first or second sleeve unit or disposed separately outside the cable system. For example, the control unit can be disposed in a user interface device, a charging station, and / or a vehicle to be charged. The first sensor unit, the second sensor unit (and more units, if needed), and the control unit may include wireless communication modules to send and receive data to and from each other via wireless internet access, Wi-Fi, Bluetooth, etc. Therefore, continuous online monitoring of the cable is possible.

[0026] In one example, the first adapter unit and / or the second adapter unit can be shaped as a handle. When the cable system is configured to charge an energy storage system, each adapter unit, which can be detachably connected to the vehicle and / or charging station, can be shaped in a user-friendly and ergonomic manner. Therefore, the first adapter unit and / or the second adapter unit can be shaped as a handle that is easy to grip, to avoid applying excessive force to the cable.

[0027] In one example, the cable system is configured to transmit high-voltage power. The cable system, specifically the cable, the first adapter unit, and the second adapter unit, can be configured to transmit power from several kV to hundreds of kV. The cable can be a high-voltage (HV) cable. Different types of HV cables can be used for various applications in instrumentation, ignition systems, and alternating current (AC) and direct current (DC) power transmission.

[0028] In one embodiment, the first sensor unit and / or the second sensor unit may include a system-on-chip design for estimating the aging condition of the cable based on locally realizable calculations / estimations.

[0029] According to this disclosure, a use of the cable system as described above is proposed. The cable system can be used to (re)charge the energy storage system of an electric vehicle. In other words, the energy storage system can be part of the electric vehicle. The vehicle can be a plug-in vehicle that can be charged from an external power source. The vehicle can be a battery-electric vehicle or a plug-in hybrid vehicle. In addition to road vehicles, the vehicle can also be any other electric vehicle powered by the energy storage system to drive its traction motor, such as rail vehicles, electric boats, and / or electric aircraft. However, the cable system is not limited to charging the energy storage system; it can also be used as an extension cable to connect at least one other cable.

[0030] Cable systems can also support bidirectional energy transfer, from vehicles to the power grid and from the power grid to vehicles, and from vehicles to vehicles.

[0031] According to this disclosure, a method for manufacturing a cable system for cable condition monitoring is proposed. The method includes...

[0032] - Provides the first adapter unit,

[0033] - Provides a first sleeve unit, which includes a first sensor unit,

[0034] - Provide a cable, which includes at least a first end, and

[0035] - A first sleeve unit is arranged between the first adapter unit and the first end of the cable.

[0036] The first adapter unit is connectable to an energy storage system. The cable is configured to transmit power to the first adapter unit. The first sleeve unit is configured to provide protection between the first adapter unit and the cable. The first sensor unit is configured to generate data based on strain applied to the first sleeve unit. The first sensor unit includes a first flexible electronic element that extends at least partially to a first end of the cable.

[0037] According to this disclosure, a method for operating a cable system is proposed. The method includes...

[0038] Connect the first adapter unit to the energy storage system of the electric vehicle.

[0039] Connect the second adapter unit to a charging station and / or energy source.

[0040] - Power is transmitted from the second adapter unit to the first adapter unit via a cable.

[0041] - Data is generated based on the strain applied to the first sleeve unit and the second sleeve unit.

[0042] - The generated data is sent to the control unit via wireless communication, and

[0043] - Estimate the aging condition of the cable based on the received data.

[0044] Alternatively, the first adapter unit and / or the second adapter unit may also be connected to another vehicle or power grid / infrastructure.

[0045] In one embodiment, the method of operation may further include estimating the aging condition of the cable based on locally achievable calculations / estimations via an on-chip system design.

[0046] In one embodiment, the operating method may employ an Internet of Things (IoT)-based approach to customize the acquisition of data required regarding customer preferences / usage patterns.

[0047] In one embodiment, the operating method may further include providing modifications to the antenna, modifications to network security, the ability to perform real-time computation and data storage, and / or redundancy for fault modes and calibration. Therefore, accurate aging measurements of the cable can be achieved.

[0048] Custom antennas can be printed onto flexible electronic components during production. This may allow for the miniaturization and integration of GSM systems-on-chips into flexible electronic components, including digital SIMs, in the foreseeable future. Custom firewalls on scalable electronic devices can ensure connections only to pre-programmed IP, with end-to-end coding.

[0049] Customized processing capabilities enable efficient monitoring functions on sensor units based on flexible electronics. Even when cloud services experience issues, the system can continue monitoring all necessary measurements and ensure safe operation.

[0050] According to this disclosure, a computer program element is proposed. When executed by an energy-saving processing element and / or solar energy, the computer program element is adapted to parse the operating method described above.

[0051] It should be noted that the above embodiments can be combined with each other, regardless of the aspects involved. Therefore, the method can be combined with structural features, and similarly, the system can be combined with the features described above regarding the method.

[0052] These and other aspects of this embodiment will become apparent from the embodiments described below and will be elucidated with reference to the embodiments described below. Attached Figure Description

[0053] Exemplary embodiments will now be described with reference to the accompanying drawings.

[0054] Figure 1 An embodiment of a cable system according to this disclosure is illustrated schematically and exemplary. Detailed Implementation

[0055] Figure 1 A cable system 10 is shown for monitoring cable conditions, such as aging. This cable system can be used to charge the energy storage system of an electric vehicle. The electric vehicle can be a plug-in vehicle that can be charged from an external power source. The electric vehicle may include modifications to vehicle-to-vehicle, vehicle-to-grid, and vehicle-to-infrastructure operations.

[0056] The cable system 10 includes a first adapter unit 1, a first sleeve unit 2, and a cable 3, the cable 3 including at least a first end 31. The first adapter unit 1 is connectable to an energy storage system, and the cable 3 is configured to transmit power to the first adapter unit 1. The first sleeve unit 2 is disposed between the first adapter unit 1 and the first end 31 of the cable 3, and is configured to provide protection between them. The first sleeve unit 2 includes a first sensor unit 4, the first sensor unit 4 being configured to generate data based on strain applied to the first sleeve unit 2. The first sensor unit 4 includes a first flexible electronic element 5 that extends at least partially to the first end 31 of the cable 3.

[0057] The first flexible electronic element 5 is configured to detect external influences affecting the cable 3 and / or the first sleeve unit 2. Specifically, the first flexible electronic element 5 is expandable and contractible based on tensile or compressive strain applied to the first sleeve unit 2. Furthermore, the first flexible electronic element 5 can also detect temperature, elasticity, humidity, gravity, ultraviolet radiation, chemical exposure, moisture intrusion, rodent attacks, etc. The first sensor unit 4 generates data based on the information detected by the first flexible electronic element 5 and sends it to the control unit 6.

[0058] The cable system 10 can be symmetrically formed, including a second adapter unit and a second sleeve unit. The second sleeve unit can be disposed between the second adapter unit and a second end of the cable 3. The second sleeve unit may include a second sensor unit configured to generate data based on strain applied to the second sleeve unit. The second adapter unit can be connected to a charging station and / or an energy source to provide power to an energy storage system.

[0059] Control unit 6 is configured to receive data generated by the first sensor unit 4 and / or the second sensor unit, and estimate the aging condition of cable 3 based on the received data. Control unit 6 is also configured to generate a warning signal based on the aging condition of cable 3 if cable 3 requires replacement, refurbishment, or repair. Control unit 6 receives data generated by the first sensor unit 4 and the second sensor unit, and sends the warning signal via wireless communication methods such as wireless internet access, Wi-Fi, and Bluetooth.

[0060] The first adapter unit 1 and / or the second adapter unit are configured as handles to facilitate the use of the cable system 10.

[0061] It should be noted that the embodiments of this disclosure are described with reference to different subjects. In particular, some embodiments are described with reference to method-type claims, while others are described with reference to device-type claims. However, those skilled in the art will understand from the above and below description that, unless otherwise stated, any combination of features related to different subjects is also considered to be disclosed with this application, in addition to any combination of features belonging to one subject. However, all features can be combined to provide synergies, and the synergies provided are not merely a simple sum of features.

[0062] While this disclosure has been illustrated and described in detail in the accompanying drawings and description, such illustrations and descriptions should be considered illustrative or exemplary rather than limiting. This disclosure is not limited to the disclosed embodiments. Other variations of the disclosed embodiments can be understood and implemented by those skilled in the art in practicing the claimed disclosure by studying the drawings, the disclosure, and the dependent claims.

[0063] In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite terms "a" or "an" do not exclude a plurality. A single processor or other unit can perform the functions of several items recounted in the claims. The fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used advantageously. Any reference numerals in the claims should not be construed as limiting the scope.

Claims

1. A cable system (10) for monitoring cable condition, comprising: - First adapter unit (1). -First sleeve unit (2), and - Cable (3), which includes at least a first end (31). The first adapter unit (1) can be connected to the energy storage system. The cable (3) is configured to transmit power to the first adapter unit (1). The first sleeve unit (2) is arranged between the first adapter unit (1) and the first end (31) of the cable (3), and is configured to provide protection between them. The first sleeve unit (2) includes a first sensor unit (4), which is configured to generate data based on the strain applied to the first sleeve unit (2). The first sensor unit (4) includes a first flexible electronic element (5) that extends at least partially to the first end (31) of the cable (3).

2. The cable system (10) according to claim 1, wherein the first flexible electronic element (5) is configured to be stretchable based on tensile strain applied to the first sleeve unit (2).

3. The cable system (10) according to claim 1 or 2, wherein the first sensor unit (4) is further configured to generate data based on the integrity of the cable (3).

4. The cable system (10) according to claim 1 or 2, wherein the first sensor unit (4) is further configured to generate data based on the temperature of the cable (3).

5. The cable system (10) according to claim 1 or 2, wherein the first sensor unit (4) is further configured to generate data based on the humidity or ultraviolet irradiation of the cable (3).

6. The cable system (10) according to claim 1 or 2 further includes a second adapter unit and a second sleeve unit, the second sleeve unit being disposed between the second adapter unit and a second end of the cable (3), the second sleeve unit including a second sensor unit configured to generate data based on strain applied to the second sleeve unit.

7. The cable system (10) according to claim 6, wherein the second adapter unit is configured to be coupled to a charging station and / or an energy source.

8. The cable system (10) according to claim 6 further includes a control unit (6) configured to receive data generated by the first sensor unit (4) and / or the second sensor unit and estimate the aging state of the cable (3) based on the received data.

9. The cable system (10) according to claim 8, wherein the control unit (6) is further configured to generate a warning signal based on the aging state of the cable (3) if the cable (3) needs to be replaced.

10. The cable system (10) according to claim 8, wherein the control unit (6) is configured to receive data from the first sensor unit (4) and / or the second sensor unit via wireless communication.

11. The cable system (10) according to claim 1 or 2, wherein the cable system (10) is configured for transmitting high-voltage power.

12. Use of the cable system (10) according to any one of the preceding claims for charging an energy storage system of an electric vehicle.

13. A method of manufacturing a cable system (10) for cable condition monitoring, comprising: - Provide a first adapter unit (1). - Provide a first sleeve unit (2), the first sleeve unit (2) including a first sensor unit (4). - Provide a cable (3), said cable (3) including at least a first end (31), and - A first sleeve unit (2) is arranged between the first adapter unit (1) and the first end (31) of the cable (3). The first adapter unit (1) can be connected to the energy storage system. The cable (3) is configured to transmit power to the first adapter unit (1). The first sleeve unit (2) is configured to provide protection between the first adapter unit (1) and the cable (3). The first sensor unit (4) is configured to generate data based on the strain applied to the first sleeve unit (2), and The first sensor unit (4) includes a first flexible electronic element (5) that extends at least partially to the first end (31) of the cable (3).

14. A method for operating a cable system (10) according to any one of claims 1 to 5, said cable system (10) further comprising a second adapter unit, a second sleeve unit, and a control unit (6), wherein, The second sleeve unit is disposed between the second adapter unit and the second end of the cable (3). The second sleeve unit includes a second sensor unit configured to generate data based on strain applied to the second sleeve unit. The control unit (6) is configured to receive data generated by the first sensor unit (4) and / or the second sensor unit and estimate the aging state of the cable (3) based on the received data. The method includes... - Connect the first adapter unit (1) to the energy storage system of the electric vehicle. Connect the second adapter unit to a charging station and / or energy source. - Power is transmitted from the second adapter unit to the first adapter unit (1) via cable (3). -Data is generated based on the strain applied to the first sleeve unit (2) and the second sleeve unit. - The generated data is sent to the control unit (6) via wireless communication, and - Estimate the aging condition of the cable (3) based on the received data.

15. A computer program element, when executed by a processing element, is adapted to perform the steps of the method of claim 14.

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