Charging Plug Temperature Sensor Circuit Protection
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Solution Overview
Problem
Conventional electric vehicle charging systems lack effective over-temperature protection, leading to damage or deformation of charging plugs and cables during faults, which can result in costly repairs and safety hazards.
Innovation Solution
An over-temperature protection system that includes a temperature sensor in the charging plug, a switch in the power circuit, and a control board in the charging device to monitor and manage temperature variations, automatically interrupting the power circuit when abnormal temperatures are detected to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse or fusible cutout is installed in the charging device to protect against charging faults, then the circuit is shut down to protect the Electric Vehicle, but the charging plug and cable inside are softened and deformed by high temperature or even broken and burnt
Solution Approach 1:
The temperature sensor is installed in the charging plug to detect temperature in advance before damage occurs. The control board continuously monitors the temperature and opens the switch to interrupt power transmission before the charging plug and cable are softened or broken by high temperature, preventing the harmful effects rather than responding after damage occurs.
Solution Approach 2:
A temperature sensor is introduced as an intermediary detection device between the power transmission path and the control system. This sensor acts as a mediator that converts temperature information into electrical signals that the control board can process, enabling early warning and intervention before thermal damage occurs to the charging plug and cable.
2Productivity
If the charging device continuously transmits power to charge the Electric Vehicle, then charging efficiency is maintained, but the charging plug and cable are exposed to high temperature risks and potential damage
Solution Approach 1:
The control board receives continuous temperature feedback from the temperature sensor mounted in the charging plug. Based on this feedback, the control board dynamically controls the switch to open or close, adjusting power transmission to prevent overheating while maintaining charging efficiency under normal conditions. This closed-loop control ensures both productivity and 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
Prevents damage to charging plugs and cables by promptly interrupting the charging process when abnormal temperatures are sensed, thereby extending the lifespan of charging system components and ensuring safety.
Implementation Method 1
a temperature sensor adapted to be mounted in a charging plug to sense a temperature of the charging plug
Data Source
AI summary
An over-temperature protection system has a control board mounted in a charging device and a temperature sensor mounted in a charging plug. A switch is coupled on a power circuit of the charging plug and controlled by the control board. When the charging plug is connected to a power supply and the charging device begins a charging operation, the control board periodically receives temperature information of the charging plug sensed by the temperature sensor. When the control board determines that the temperature of the charging plug is abnormal, the switch is open to interrupt the power circuit so as to stop the charging operation for ensuring safety of the charging device.