EV Charging Plug Housing Crack Detection With Conductive Paths
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Solution Overview
Problem
Existing electric vehicle charging plugs lack continuous monitoring of mechanical integrity, leading to increased risks of user electric shock and potential fires due to undetected cracks in the plug housing.
Innovation Solution
An electric vehicle charging plug with a housing containing a sensor with at least one conductive path embedded in or on the surface, connected to a control unit that measures changes in resistance or other characteristics to detect cracks in the housing, thereby preventing electric shock and ensuring safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If temperature sensors are used to detect overheating, then fire prevention is improved, but crack detection capability remains insufficient
Solution Approach 1:
The patent combines temperature sensing and crack detection functions into a single integrated sensor system. The sensor includes both a temperature sensor and a conductive path that can detect cracks, allowing simultaneous monitoring of thermal conditions and structural integrity without requiring separate independent systems.
Solution Approach 2:
The sensor is designed with multi-functionality to perform both temperature monitoring and crack detection. The conductive path serves dual purposes: it acts as an electrical connection element and simultaneously functions as a crack detection mechanism through resistance measurement, eliminating the need for separate dedicated crack sensors.
2Reliability
If multiple sensors are added for comprehensive monitoring, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple monitoring functions into a single integrated sensor assembly. The temperature sensor and crack detection conductive path are combined in one component, reducing the number of separate sensors needed while maintaining comprehensive safety monitoring capabilities.
Solution Approach 2:
The sensor system is designed with universal multi-functionality where the conductive path serves both as an electrical connector and a crack detection element. This multi-functional design reduces overall system complexity by eliminating redundant components that would otherwise be needed for separate functions.
3Measurement precision
If conductive paths are embedded in housing walls, then crack detection precision is improved, but manufacturing difficulty increases
Solution Approach 1:
The conductive paths are pre-formed and positioned within the housing structure during the manufacturing process. By preparing the conductive path configuration in advance and integrating it into the housing mold or structure before final assembly, the patent achieves precise crack detection positioning without requiring complex post-manufacturing operations.
Solution Approach 2:
The patent integrates conductive materials into the housing structure, creating a composite construction where the housing and conductive path form a unified component. This approach allows the conductive path to be embedded within or on the housing surface during manufacturing, achieving both precision crack detection and manufacturing efficiency through material integration.
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
The solution enables continuous monitoring of the plug's mechanical integrity, preventing electric shocks and potential fires, while also reducing downtime and improving the reliability and efficiency of the charging process.
Implementation Method 1
a sensor (4) comprising at least one conductive path (5) embedded in a wall or arranged on a surface of the housing (2) or the main housing (3)... the sensor (4) is configured to detect the crack of the housing (2) for connecting to an electric vehicle or the main housing (3)
Data Source
AI summary
An electric vehicle charging plug includes a housing for connecting to an electric vehicle, a main housing, a sensor comprising at least one conductive path embedded in a wall or arranged on the surface of the housing and/or main housing, and a control unit wherein the sensor is configured to detect the crack of the housing and/or the main housing.