Charging Plug Liquid Detection for High-Power EV Safety
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Solution Overview
Problem
Charging plugs and stations face risks of overheating and liquid leakage, which can lead to short circuits and safety hazards during high-power charging, particularly with standardized connections that are not easily adaptable for increased charging currents.
Innovation Solution
Incorporating a liquid detection apparatus with a conductor track structure within the charging plug's housing to identify and prevent liquid accumulation, allowing for autonomous termination of the charging process and integration with a control unit to ensure safety measures are taken, such as power supply termination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If active cooling is implemented to enable high charging power, then charging power can be increased, but the risk of cooling fluid leakage and power contact shorting increases
Solution Approach 1:
The liquid detection apparatus is installed in advance within the housing to detect liquid accumulation before it can cause a short circuit. The detector proactively monitors for cooling fluid leakage and triggers safety measures before damage occurs, preventing the harmful effect rather than reacting to it after the fact.
Solution Approach 2:
The liquid detection apparatus provides continuous feedback about the presence of liquid in the housing to the control unit. This feedback mechanism enables the control unit to monitor the cooling system status and automatically terminate charging when liquid is detected, creating a closed-loop safety system that responds to actual conditions.
2Adaptability or versatility
If standardized plug connections are used, then compatibility with multiple vehicles is improved, but the ability to increase charging current is limited
Solution Approach 1:
The invention changes the parameter of charging current capability by implementing an actively cooled charging plug with liquid detection. This allows the standardized plug to safely handle higher currents (up to 350 amperes) by actively managing heat dissipation through cooling fluid circulation, thereby increasing power transmission capability within the standardized connection framework.
3Productivity
If high charging currents up to 350 amperes are transmitted, then charging speed is improved, but heat generation and overheating risk increase
Solution Approach 1:
The invention uses a cooling fluid circulation system with cooling channels to actively remove heat from the plug connection region. The hydraulic cooling system circulates coolant through channels in the housing, efficiently dissipating the heat generated by high charging currents and maintaining safe operating temperatures during rapid charging.
Solution Approach 2:
The cooling system exploits thermal management principles to handle the heat generated during high-power charging. By circulating cooling fluid through the housing channels, the system continuously removes thermal energy from the plug connection region, preventing thermal buildup that would otherwise limit charging speed or cause damage.
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 enhances safety by preventing power contact shorts due to liquid and allows for high-power charging up to 350 amperes while maintaining safety, even in the presence of cooling fluid leakage or housing damage, thereby ensuring a rapid and secure charging process.
Implementation Method 1
a charging plug (2) having a housing (4) for accommodating power contacts (6) and having power contacts (6) for power transmission, wherein the charging plug (2) has an apparatus (10) for detecting liquid, which apparatus (10) is configured to detect liquid collecting inside the housing (4)
Data Source
AI summary
A charging plug, having a housing for accommodating power contacts andpower contacts for power transmission, and havingan apparatus for detecting liquid, which apparatus is configured to detect liquid collecting inside the housing.