EV Charging Shutdown Threshold Control to Prevent Fuse Blowouts

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Solution Overview

Problem

Existing power supply devices for electric vehicles lack effective methods to prevent damage by preventing excessive charging currents and voltages, and fail to adapt to the varying charging parameters of different vehicles, leading to fuse blowouts and potential battery damage.

Innovation Solution

A method that dynamically adjusts an emergency shutdown threshold based on real-time data exchange with the energy storage device, allowing for early intervention to prevent fuse activation and protect the power supply and energy storage devices from damage by interrupting the power circuit when charging parameters exceed predefined limits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fuse is used to interrupt the power circuit in the event of a malfunction, then the power circuit is protected from damage, but the fuse must be replaced after just a few switching operations or is even destroyed the first time it blows, rendering the electric vehicle non-functional

Engineering Contradiction:

Improvepower circuit protectionVSAvoidfuse replacement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The control device determines an actual emergency shutdown threshold before the charging process based on limit charging parameters from the energy storage device. This preliminary setting of the shutdown threshold enables early intervention before fuse activation is necessary, preventing the harmful effect of fuse blowouts while maintaining power circuit protection

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If a power supply device uses a fixed shutdown threshold, then the device structure is simple, but it cannot adapt to different energy storage devices with varying charging parameters, causing fuses to blow unnecessarily

Engineering Contradiction:

Improveshutdown threshold settingVSAvoidcharging parameter adaptation

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The emergency shutdown threshold is dynamically adjusted based on the specific energy storage device being charged. The control device determines the actual emergency shutdown threshold individually for each energy storage device using its limit charging parameters, enabling the power supply device to adapt to different vehicles without increasing structural complexity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The shutdown threshold parameter is changed from a fixed value to a variable value that depends on the limit charging parameters of the connected energy storage device. This parameter adaptation allows the power supply device to work with different vehicle types while preventing unnecessary fuse activation

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If the power supply device does not know the triggering characteristics of the electric vehicle's fuse, then the device can charge a wide variety of vehicles, but it cannot be protected from fuse blowouts during discharging processes

Engineering Contradiction:

Improvevehicle compatibilityVSAvoidprotection from fuse blowouts

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The control device determines the actual emergency shutdown threshold before the charging process based on limit charging parameters exchanged during data transmission. This preliminary action enables the power supply device to protect against fuse blowouts without needing to know specific fuse characteristics, maintaining vehicle compatibility while improving reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The actual emergency shutdown threshold acts as an intermediary parameter that translates the energy storage device's limit charging parameters into protective action. This intermediary enables protection without requiring direct knowledge of fuse characteristics, allowing the system to work with various vehicle types

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4631767A1Method for operating an electric power supply device, shut-down control device, shut-down device, and power supply device

Publication Date: 2025.10.15 ADS TEC ENERGY GMBH

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AI summary

The invention relates to a method for operating an electrical power supply device (1) for unidirectionally or bidirectionally charging an energy storage device (2), wherein - during a charging process, data from a data transmission between the power supply device (1) and the energy storage device (2) are received, wherein the data contain at least one limit charging parameter characteristic of the charging process, wherein - depending on the at least one limit charging parameter, an actual emergency shutdown threshold of the power supply device (1) is set for a charging parameter, wherein - if the charging parameter exceeds the actual emergency shutdown threshold, an emergency measure is carried out in order to protect the power supply device (1) and/or the energy storage device (2) from damage.The invention also relates to a shutdown control device (5) for carrying out such a method, a shutdown device with such a shutdown control device (5) and a power supply device (1) with such a shutdown control device (5) and/or such a shutdown device.