Pre-filled Charging Cable Cooling Unit for Electric Filling Stations
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Solution Overview
Problem
Existing charging cable cooling systems for electric vehicle charging stations are prone to wear and require time-consuming and error-prone installation and maintenance, involving filling and venting of cooling liquids, which can be costly and inconvenient.
Innovation Solution
A charging cable unit with a pre-filled cooling system that connects only via a heat exchanger to the charging column's coolant circuit, using quick couplings and a high-position cooling unit for easy mounting, allowing the cable to be threaded into the column without venting, and secured with clamping and supporting elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a liquid cooling system is integrated into the charging cable, then cooling efficiency is improved, but installation and maintenance complexity increases due to filling and venting requirements
Solution Approach 1:
The cooling system is segmented into a reusable charging cable unit and a stationary charging column unit. The cable contains its own sealed cooling circuit with cooling liquid already filled during manufacturing, while the column provides a refilling station. This segmentation allows the cable to be easily replaced without maintenance, as the complex filling and venting operations are performed only once at the column during initial setup or cable replacement.
Solution Approach 2:
The cooling circuit is pre-filled with cooling liquid during manufacturing before the cable is delivered to the customer. This preliminary action eliminates the need for on-site filling and venting operations, allowing the cable to be simply connected to the column and immediately operational. The column's refilling station is prepared in advance to automatically refill the cable when needed.
2Reliability
If the cooling system requires on-site filling and venting, then cooling liquid can be replenished, but maintenance time and error risk increase
Solution Approach 1:
The charging column is equipped with an automatic refilling station that performs the filling and venting operations autonomously when a cable is connected. The system self-regulates the cooling liquid transfer from the column's storage tank to the cable's cooling circuit, eliminating the need for manual intervention by maintenance personnel. This self-service capability significantly reduces maintenance time and eliminates human error in the filling and venting processes.
Solution Approach 2:
The charging column acts as an intermediary between the cooling liquid storage and the cable cooling circuits. Instead of requiring direct manual connection and manipulation of the cable's cooling system, the column provides a standardized refilling interface that mediates the complex filling and venting operations, simplifying the maintenance process for users.
3Reliability
If plug connectors with valves are used to prevent leakage, then sealing is improved, but cost and sensitivity increase
Solution Approach 1:
The sealing function is segmented between the cable's built-in sealed cooling circuit and the column's refilling station. The cable connector is designed with an integrated sealed cooling liquid reservoir and connection interface that maintains sealing without requiring complex valves in the plug connector itself. The column's refilling station provides the necessary valve and control mechanisms in a stationary location where complexity is acceptable.
Solution Approach 2:
The column's refilling station serves as an intermediary that handles the complex valve and sealing operations during the refilling process. The cable connector itself remains relatively simple, relying on the column's sophisticated refilling mechanism to ensure proper sealing and prevent leakage during the maintenance operation.
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
Facilitates quick and error-free mounting of the charging cable unit, reducing maintenance time and costs by eliminating the need for on-site filling and venting, while maintaining efficient cooling through a sealed and flexible cable routing system.
Implementation Method 1
the cooling system of the charging cable is connected only via a heat exchanger to a liquid cooling circuit of the charging column
Data Source
AI summary
A charging cable unit for a charging column of an electric filling station has a cooling unit and a charging cable which is preferably provided with cable shoes. The coding unit includes a heat exchanger with first connections and second connections. The charging cable has a secondary coolant circuit that is fluidically connected to the second connections. The cooling unit is designed to cool the secondary coolant circuit if the first connections are fluidically connected to a common primary coolant circuit of the electric filling station. Also described is a mounting method using such a charging cable unit.