EV Charging Plug Temperature Control Using Ambient Compensation
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Solution Overview
Problem
Charging systems for electric vehicles often incorrectly shut down or reduce charging due to temperature fluctuations, leading to inefficiencies in very cold or warm environments, as they fail to accurately account for ambient temperatures and component heating rates.
Innovation Solution
A charging system that incorporates ambient temperature sensors and an electronic control device to monitor the difference temperature between current-carrying components and ambient conditions, outputting control signals to adjust the charging current based on predetermined limit difference temperatures and time profiles, thereby preventing unnecessary shutdowns or reductions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If charging current is limited to 200 A continuous load, then temperature increase is limited to 50 K per IEC standard, but charging efficiency is reduced compared to cooled systems
Solution Approach 1:
The charging system dynamically adjusts the charging current based on real-time temperature measurements from both ambient and current-carrying component sensors. This allows the system to safely exceed the conservative 200 A continuous load limit when conditions permit, optimizing charging efficiency while maintaining temperature control within acceptable limits.
Solution Approach 2:
The control device continuously receives feedback from temperature sensors and adjusts charging current accordingly. This closed-loop control enables the system to maintain temperature increase within the 50 K limit while maximizing charging current, achieving both safety compliance and high charging efficiency without requiring active cooling.
2Device complexity
If temperature monitoring is performed without ambient temperature compensation, then device complexity is reduced, but measurement precision deteriorates in varying environmental conditions
Solution Approach 1:
The temperature monitoring system is segmented into two independent measurement functions: ambient temperature sensing and current-carrying component temperature sensing. This segmentation allows each sensor to be optimized for its specific measurement task, improving overall measurement precision without excessive complexity.
Solution Approach 2:
The control device performs multiple functions: it controls charging current, monitors component temperature, and compensates for ambient temperature effects. By integrating these functions into a single control unit, the system achieves high measurement precision and control accuracy without requiring separate complex subsystems.
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
This solution ensures more accurate temperature monitoring and control, reducing incorrect shutdowns and maintaining efficient charging operations across varying environmental conditions, while accounting for historical temperature data and component heating profiles.
Implementation Method 1
a plurality of temperature sensors (12, 22) are provided, each designed to determine a temperature of a current-carrying component (11, 20) of the charging system (1)
Implementation Method 2
an ambient temperature sensor (33) is provided, which is designed to determine an ambient temperature of the charging system (1)
Implementation Method 3
Due to the charging currents flowing through the power contacts, they inevitably heat up due to ohmic heat losses
Data Source
Figure 1
AI summary
The invention relates to a charging system (1) for transmitting an electric charge current to an energy receiver. The charging system (1) has the following: - a charge plug (10) for coupling to a corresponding connection device; - an electronic controller (31); and - at least one temperature sensor (12, 22) for determining the temperature of a current-conducting component (11, 20) of the charging system (1), wherein the temperature sensor (12, 22) is coupled to the electronic controller (31) in order to output temperature measurement data which represents the temperature of the current-conducting component (11, 20). The charging system (1) is characterized by the following features: - the charging system (1) additionally has an ambient temperature sensor (33) for determining the ambient temperature of the charging system (1); - the ambient temperature sensor (33) is coupled to the electronic controller (31) in order to output ambient temperature data which represents the ambient temperature of the charging system (1); and - the electronic controller (31) is designed to ascertain a differential temperature between the temperature of the current-conducting component (11) and the ambient temperature on the basis of the temperature measurement data and the ambient temperature measurement data and to output a control signal on the basis of the ascertained differential temperature in order to control the charge current.