EV Charging Plug Sensor Carrier for Accurate Contact Temperature Sensing
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Solution Overview
Problem
Existing charging plugs for electric vehicles experience significant measurement inaccuracies due to environmental changes, leading to premature or delayed charging process cancellations during high-power direct current charging.
Innovation Solution
A charging plug design featuring a sensor carrier that securely positions a temperature sensor at a defined distance from the power contact, using a positive connection and casting compound to ensure consistent measurement accuracy, reducing error deviations and protecting against moisture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed close to power contacts for accurate temperature monitoring, then measurement precision improves, but measurement accuracy deteriorates due to environmental changes and positioning variability
Solution Approach 1:
The sensor carrier is pre-positioned at a defined distance from the power contact during manufacturing, establishing a consistent reference point before actual temperature measurement begins. This preliminary positioning action eliminates variability in sensor placement that would otherwise occur during installation or operation.
Solution Approach 2:
The sensor carrier acts as an intermediary component between the sensor and the power contact. It provides a stable mounting structure that maintains a defined spatial relationship, mediating the interaction between the sensor and the thermal field while protecting against environmental interference.
2Reliability
If sensors are positioned at a defined distance from power contacts, then measurement reliability improves, but device complexity increases due to additional sensor carrier structure
Solution Approach 1:
The sensor carrier integrates multiple functions into a single component: it provides mechanical support for the sensor, establishes the defined distance from the power contact, and protects the sensor from environmental factors. By merging these functions, the design avoids adding separate structures for each purpose.
Solution Approach 2:
The sensor carrier serves multiple purposes within the charging connector: it positions the sensor accurately, maintains a defined distance from the power contact, protects the sensor from moisture and environmental changes, and provides a mounting structure. This multi-functionality reduces the need for additional specialized components.
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 improved sensor positioning and fixation within the charging plug enhance measurement reliability, reducing incorrect charging terminations and ensuring more precise temperature monitoring of power contacts.
Implementation Method 1
a sensor which is designed to detect the temperature of the power contact
Data Source
Figure 1a~1b
Figure 2~3a
Figure 3b~4
AI summary
The invention relates to a charging plug (100), in particular a fast-charging plug, for charging a battery, especially a traction battery of an electric vehicle. The charging plug (100) according to the invention has at least one power contact (13) configured to transfer current to the battery, wherein the power contact (13) has a contact tab (135). Furthermore, a contact carrier (16) is provided in the charging plug (100) in which the power contact (13) is at least partially arranged, wherein in particular a contact section (131) of the power contact (13) projects out of the contact carrier (16).Furthermore, according to the invention, the charging plug (100) has at least one sensor carrier (134) which is designed to accommodate a sensor (17), in particular a temperature sensor, in a pocket (134a) provided for this purpose and is designed and arranged such that the sensor (17) is positioned at a defined distance from the power contact (13).