Charging Inlet Terminal Temperature Sensor Nesting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing charging inlet assemblies for electric and hybrid electric vehicles face latency issues in temperature sensing due to the remote location of temperature sensors from the mating interface, which can lead to inadequate monitoring of terminal temperatures during charging.
Innovation Solution
Incorporating a temperature sensor assembly within the terminal, axially aligned with the mating interface, to directly sense the temperature of the pin, eliminating latency problems and enabling more accurate temperature monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is located at the rear end of the terminal spaced a distance from the mating interface, then the sensor is easier to install and access, but the temperature sensing has latency and does not accurately reflect the temperature at the mating interface
Solution Approach 1:
The temperature sensor assembly is nested within a temperature sensor channel that extends through the terminal body. The sensor is received inside the channel and positioned axially aligned with the mating interface, allowing the sensor to be contained within the terminal structure while maintaining close proximity to the heat source for accurate temperature measurement.
Solution Approach 2:
The temperature sensor channel acts as an intermediary structure that facilitates the insertion and positioning of the temperature sensor. The channel provides a guided pathway from the rear of the terminal to the mating interface area, enabling the sensor to reach its optimal sensing position without requiring complex external mounting arrangements.
2Reliability
If the temperature sensor is located close to the mating interface, then the temperature sensing accuracy is improved, but the sensor is more difficult to access for installation and maintenance
Solution Approach 1:
The temperature sensor channel is pre-formed as an integral part of the terminal structure during manufacturing. This preliminary action creates a ready-made pathway that guides the sensor assembly into its final position, eliminating the need for complex installation procedures while ensuring the sensor is correctly positioned for reliable temperature monitoring.
Solution Approach 2:
The temperature sensor is designed as a separate, extractable component that can be removed from the temperature sensor channel. This extraction capability allows the sensor to be accessed for installation, replacement, or maintenance by simply withdrawing it from the channel, which otherwise provides protected positioning close to the mating interface.
3Ease of repair
If the pin is made replaceable for long-term serviceability, then the ease of repair is improved, but the device complexity increases due to the separable mating interface
Solution Approach 1:
The terminal is segmented into distinct components: a head portion that remains permanently installed in the housing, and a replaceable pin portion that can be removed and replaced at the mating interface. This segmentation allows the pin to be serviced independently without replacing the entire terminal assembly, improving ease of repair while maintaining a relatively simple overall structure.
Solution Approach 2:
The mating interface is designed with dynamic characteristics that allow the pin to be easily inserted and removed. The separable connection provides flexibility for maintenance operations while maintaining secure electrical and mechanical connection during normal operation, balancing ease of repair with structural integrity.
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 provides real-time and accurate temperature sensing close to the heat source, preventing overheating damage and ensuring safe charging operations by allowing for timely intervention when temperature thresholds are exceeded.
Implementation Method 1
The temperature sensor is axially aligned with the separable mating interface of the pin within an interior of the terminal for sensing a temperature of the pin
Data Source
AI summary
A terminal for a charging inlet assembly includes a head secured in a terminal channel of a housing of the charging inlet assembly having a terminating end configured to be terminated to a power cable. The head has a temperature sensor channel extending longitudinally therethrough open at the rear of the terminal. The terminal includes a pin at a front of the terminal. The pin has an outer surface defining a separable mating interface for mating engagement with a charging conductor of a charging connector. The terminal includes a temperature sensor assembly received in the temperature sensor channel. The temperature sensor assembly includes a temperature sensor and a lead extending from the temperature sensor through the temperature sensor channel. The temperature sensor is axially aligned with the separable mating interface of the pin within an interior of the terminal for sensing a temperature of the pin.