Hybrid Vehicle Charger Temperature Estimation via Refrigerant Cooling
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Solution Overview
Problem
Existing plug-in vehicles face inefficiencies in battery charging due to faulty operations in temperature sensors during slow charging, leading to reduced system efficiency and potential damage to charging devices.
Innovation Solution
A method and system that determine normal refrigerant circulation and coolant levels to estimate the charger's temperature using a heat dissipation device's temperature, allowing the charger to adjust its output and continue slow charging even with a malfunctioning temperature sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the vehicle stops charging when a temperature sensor fault is detected, then the power device is protected from damage, but the charging efficiency and system productivity decrease
Solution Approach 1:
The patent uses the coolant temperature as an intermediary parameter to substitute for the faulty OBC temperature sensor readings. By monitoring the coolant temperature through the existing temperature sensor and using it to infer OBC temperature conditions, the system can make informed charging decisions without relying on the defective sensor, thus maintaining both safety and charging productivity
Solution Approach 2:
The patent creates a virtual copy of the temperature monitoring function by using coolant temperature data to represent OBC temperature conditions. This copying approach allows the system to replicate the temperature monitoring capability through an alternative measurement source, enabling continuous charging operation even when the original temperature sensor fails
2Measurement precision
If a separate temperature sensor is added to monitor OBC temperature, then measurement precision improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent makes the existing coolant temperature sensor serve multiple functions: it monitors both the coolant temperature for cooling system control and provides indirect temperature information for OBC safety monitoring. This multi-functionality eliminates the need for a dedicated OBC temperature sensor, reducing device complexity while maintaining measurement capability
Solution Approach 2:
The system uses its existing cooling system infrastructure and temperature sensor to simultaneously perform both coolant temperature monitoring and OBC temperature assessment. The cooling system serves itself by providing temperature data that benefits both its primary cooling function and the secondary OBC monitoring function, eliminating redundant components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous and efficient slow charging by eliminating the need for separate hardware, increasing vehicle reliability and reducing production costs while preventing overheating.
Implementation Method 1
a refrigerant circulation device configured to circulate the refrigerant along a cooling channel
Implementation Method 2
estimate a temperature of the charger using a temperature of a heat dissipation device of the controller through which the refrigerant passes
Data Source
AI summary
A plug-in vehicle capable of wired-charging a battery through a charging connector using an external charger and a method for controlling the same are provided. The method for controlling charging of a vehicle configured to perform a charging operation using external power includes determining whether a refrigerant circulation device operates normally and the amount of refrigerant is normal when a temperature sensor of a charger malfunctions. When the refrigerant circulation device operates normally and the amount of refrigerant is normal, a temperature of the charger is estimated using a temperature of a heat dissipation device through which the refrigerant passes and the output of the charger is adjusted based on the estimated temperature.