Connector Contact Failure Detection via Temperature Differential
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Solution Overview
Problem
Existing contact failure detection methods in power storage systems are affected by ambient temperature, making it difficult to distinguish between temperature increases due to contact resistance and environmental factors, which can lead to delayed detection and increased risk of smoking or fire.
Innovation Solution
A contact failure detection system that uses temperature sensors to measure temperature changes at connector contacts and ambient temperature, determining a failure if the difference in temperature change exceeds a set value, allowing for accurate detection independent of environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature monitoring is used to detect contact failure, then contact failure can be detected, but the detection accuracy is affected by ambient temperature changes
Solution Approach 1:
The patent introduces an ambient temperature sensor as an intermediary element to measure the environmental temperature. This mediator allows the system to distinguish between temperature changes caused by contact resistance and those caused by ambient conditions, thereby resolving the interference problem and improving detection accuracy.
Solution Approach 2:
The system implements feedback by continuously monitoring both connector temperature and ambient temperature, then using the ambient temperature data to adjust the threshold for contact failure detection. This feedback mechanism enables the system to adapt to changing environmental conditions and maintain high detection accuracy throughout operation.
2Reliability
If visual inspection of connector contacts is performed, then contact failures can be detected, but the inspection cannot be continuously monitored and requires system shutdown
Solution Approach 1:
The patent replaces the mechanical visual inspection method with a thermal sensing system. Temperature sensors continuously monitor the connector contacts, eliminating the need for physical inspection and allowing detection to occur during normal system operation without requiring shutdown or direct access to the connectors.
Solution Approach 2:
The temperature monitoring system enables continuous detection of contact failures during normal operation. Unlike visual inspection which requires periodic shutdowns, the thermal sensing system operates continuously, providing uninterrupted monitoring and immediate detection of contact resistance increases.
3Measurement precision
If temperature threshold is set low for early detection, then detection sensitivity increases, but false alarms increase due to ambient temperature variations
Solution Approach 1:
The system uses feedback from ambient temperature sensors to dynamically adjust detection thresholds. By continuously comparing connector temperature changes with ambient temperature changes, the system can distinguish between normal environmental variations and actual contact failures, reducing false positives while maintaining high sensitivity.
Solution Approach 2:
The detection threshold is made dynamic rather than fixed. The system continuously adapts the threshold based on real-time ambient temperature conditions, allowing the detection criteria to change with environmental conditions. This dynamic approach maintains high sensitivity while automatically compensating for ambient variations to prevent false alarms.
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
Enables early and accurate detection of contact failures, reducing the risk of system damage and ensuring safety by distinguishing temperature changes caused by contact resistance from environmental factors.
Implementation Method 1
a temperature sensor to detect a temperature at a contact between a live part of a connector for a first circuit device and a live part of a connector for a second circuit device
Implementation Method 2
a controller to determine occurrence of a contact failure between the live parts if a difference between an amount of change in temperature detected by the temperature sensor per predetermined time and an amount of change in ambient temperature per predetermined time is greater than a set value
Data Source
AI summary
A temperature sensor detects a temperature at a contact between a live part of connector for a first circuit device and a live part of a connector a for second circuit device. A controller determines the occurrence of a contact failure between the live parts if a difference between an amount of change in temperature detected by the temperature sensor per predetermined time and an amount of change in ambient temperature per predetermined time is greater than a set value.