EV Charging Plug Dock Cooling for Fast-Charge Heat Control
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Solution Overview
Problem
Existing charging devices for electric vehicles face challenges in simplifying the connector assembly and charging line design, particularly in managing heat generated during fast charging, which can lead to overheating and disrupt the charging process.
Innovation Solution
A charging device with a cooling device integrated into the docking station, allowing the charging plug to be pre-cooled to a predetermined temperature before use, using air, liquid, or electrical cooling methods, thereby eliminating the need for cooling hoses in the charging line and simplifying the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling hoses are integrated into the charging line to cool the charging plug during fast charging, then the charging plug temperature is controlled, but the device complexity and design difficulty increase
Solution Approach 1:
The cooling device is extracted from the charging line and relocated to the docking station. The charging line is simplified to only perform its primary function of power transmission, while the docking station assumes the cooling function through integrated cooling elements that act on the charging plug during insertion and storage.
Solution Approach 2:
The docking station serves as an intermediary system that provides cooling to the charging plug indirectly. Instead of complex internal cooling channels within the charging plug or cable, the docking station acts as an external cooling medium that cools the plug when it is docked, preparing it for subsequent charging operations.
2Temperature
If cooling components are integrated into the charging plug to manage heat during fast charging, then temperature control is achieved, but the connector assembly complexity increases
Solution Approach 1:
Cooling components are extracted from the charging plug assembly and relocated to the docking station. The charging plug is simplified to focus on electrical connection functions, while thermal management is handled by the docking station's cooling elements that interact with the plug during docking operations.
Solution Approach 2:
The docking station provides self-service cooling to the charging plug during its idle period in the dock. The cooling system automatically activates when the plug is docked, preparing it thermally for upcoming charging operations without requiring complex active cooling systems within the plug itself.
3Reliability
If active cooling is implemented during charging to prevent overheating, then charging reliability is improved, but the system complexity and energy consumption increase
Solution Approach 1:
Cooling is performed in advance during the idle period when the charging plug is docked and not in use. The docking station's cooling elements pre-cool the charging plug before the next charging operation begins, ensuring the plug is thermally prepared to handle high-power charging without requiring active cooling during the charging process itself.
Solution Approach 2:
Cooling is applied periodically during the idle periods between charging operations, rather than continuously during charging. The docking station's cooling system activates when the plug is docked and inactive, providing thermal management in a periodic manner that simplifies the overall system while maintaining reliability.
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 enables efficient cooling of the charging plug, preventing overheating, ensuring error-free and uninterrupted charging, even in high ambient temperatures, and allows for quicker charging by maintaining the plug at an optimal temperature, thus enhancing the reliability and efficiency of the charging process.
Implementation Method 1
The cooling device can be designed and/or selected in such a way that it corresponds to the frequency of use of the charging device
Implementation Method 2
The period of time between driving away and the subsequent vehicle driving up can be used to cool the charging plug
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a charging device for an energy storage device of an electrically driven vehicle, comprising a charging plug (12) for transferring an electrical charge to the energy storage device of the motor vehicle, a charging line (14) for connecting the charging plug (12) to a power grid, and a charging column (16 ) with a docking station (18) for receiving the charging plug (12) when not in use and for connecting the charging line (14) to the mains, a cooling device for cooling the charging plug (12) being arranged in the docking station (18). As a result, the structure of the charging device can be simplified.