Vehicle Charging Plug Overheat Detection by Temperature Rise Rate
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Solution Overview
Problem
Existing in-cable control boxes (ICCBs) struggle to detect sudden overheating events at vehicle charging plugs due to increased contact resistance from foreign substances or aged electrical outlets, leading to a high risk of fires.
Innovation Solution
Implement a method and apparatus that monitor the temperature of the plug connected to an electrical outlet, calculate the average change in temperature per unit time, and cut off charging if the change exceeds a preset threshold range, using analog-digital conversion and a time counter to detect rapid temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are embedded in the ICCB plug to detect overheating, then safety monitoring capability is improved, but the ability to detect sudden overheating caused by contact resistance increase deteriorates
Solution Approach 1:
The patent performs preliminary actions by continuously monitoring temperature at high frequency and calculating the rate of temperature change before dangerous overheating occurs. This allows the system to detect sudden temperature increases caused by contact resistance and cut off power before the temperature reaches dangerous levels, resolving the contradiction between having temperature sensors and detecting sudden overheating events.
2Ease of manufacture
If the ICCB structure is simplified for ease of manufacture, then manufacturing cost is reduced, but the ability to detect overheating caused by foreign substances or aged outlets deteriorates
Solution Approach 1:
The patent replaces complex mechanical structures with intelligent software algorithms. Instead of adding complex mechanical detection structures to the ICCB, the system uses a processor to analyze temperature data and calculate the rate of change, enabling fire prevention through computational logic rather than mechanical complexity, thus maintaining ease of manufacture while improving reliability.
3Reliability
If traditional temperature sensors are used in the ICCB plug, then basic temperature monitoring is achieved, but detection of rapid temperature increase before fire occurrence deteriorates
Solution Approach 1:
The patent implements continuous feedback by monitoring temperature at high frequency and calculating the rate of temperature change in real-time. This feedback mechanism allows the system to detect rapid temperature increases and trigger protective actions before dangerous conditions develop, resolving the contradiction between basic temperature monitoring and rapid response capability.
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
Effectively prevents overheating and potential fires by detecting temperature changes before they reach dangerous levels, even in situations where traditional sensors fail to recognize rapid increases.
Implementation Method 1
a thermistor is generally applied to monitor a temperature
Implementation Method 2
performing analog-digital conversion on the temperature of the plug
Implementation Method 3
heat is generated by an increase in contact resistance
Data Source
AI summary
An embodiment method of detecting overheating during charging of a vehicle includes monitoring a temperature of a plug connected to an electrical outlet configured to supply a charging voltage for charging a battery of the vehicle, determining an average amount of change in temperature of the plug per unit time based on the temperature of the plug, and cutting off charging in response to the average amount of change in temperature of the plug per unit time exceeding a preset threshold range.