Charging Connector Evaluation Jig for Accurate Temperature Rise Testing
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Solution Overview
Problem
The existing evaluation methods for heat generation at the connecting portion of charging connectors are inaccurate due to variations in male and female terminal specifications, making it difficult to assess the temperature rise during current passage, especially during rapid charging with large currents.
Innovation Solution
An evaluation jig with a pair of female terminals connected by an electric wire having a cross-sectional area of 70 mm² to 95 mm² and a length of 2 m or more, which minimizes the impact of the wire's heat radiation characteristics, allowing for accurate temperature rise evaluation at the connecting portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a standard electric wire is used to connect the female terminals, then the evaluation setup is simple, but the wire's heat radiation characteristics affect the measurement accuracy of temperature rise at the connecting portion
Solution Approach 1:
The patent specifies precise parameter ranges for the electric wire: cross-sectional area of 70 mm² or more and 95 mm² or less, and length of 2 m or more. By controlling these parameters, the wire's heat radiation characteristics are minimized, allowing accurate measurement of temperature rise at the connecting portion without interference from the wire itself.
2Adaptability or versatility
If different male terminals with different specifications are used, then various charging connector types can be evaluated, but it becomes difficult to obtain consistent and accurate heat generation data
Solution Approach 1:
The patent introduces a standardized evaluation jig with specifically dimensioned electric wires as an intermediary between the charging connector and the measurement system. This intermediary component isolates the measurement from variations in different male terminal specifications, enabling consistent and accurate heat generation evaluation across different charging connector types.
3Measurement precision
If a long electric wire is used to reduce heat radiation effect, then measurement accuracy improves, but the wire occupies more space and increases setup complexity
Solution Approach 1:
The patent determines through research that a wire length of 2 m or more is the threshold at which the heat radiation effect becomes negligible. This specific parameter threshold provides a clear design criterion that balances measurement accuracy requirements with practical space constraints in evaluation environments.
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 setup enables precise evaluation of heat generation at the connecting portion of charging connectors, allowing for effective design of terminals to manage temperature within acceptable limits during high-current charging.
Implementation Method 1
Heat generated at a connecting portion of one male terminal and one female terminal when a current passes therethrough may be transmitted via the electric wire to a connecting portion of the other male terminal and the other female terminal
Implementation Method 2
A connecting portion of a charging connector, as disclosed in Japanese Patent Laying-Open No. 2019-187035, and a charging inlet of a vehicle generates heat due to contact resistance when a current is passed
Data Source
AI summary
The evaluation jig includes a pair of female terminals connectable to a pair of male terminals of a charging connector and an electric wire that connects the paired female terminals to each other. The electric wire has a cross-sectional area of 70 mm2 or more and 95 mm2 or less. The electric wire has a length of 2 m or more.