Connector Contact Temperature Detection via Potential Difference
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Solution Overview
Problem
Indirect temperature measurement at the contact point of high-power connectors is unreliable and slow, leading to potential damage due to overheating, especially in applications like electric vehicle charging, where currents exceed 100 A and rapid temperature detection is critical.
Innovation Solution
A connector system that includes a connector tap and/or a mating connector contact probe to directly measure the potential difference between the connector and mating connector contact elements, allowing for direct determination of the contact point temperature using the relationship between potential difference, resistivity, and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If indirect temperature measurement is used with a temperature sensor located close to the contact point, then the device complexity is reduced, but the measurement precision and response speed deteriorate
Solution Approach 1:
The patent replaces the mechanical/thermal measurement system (temperature sensor physically contacting or near the contact point) with an electrical measurement system. By measuring the potential difference between the connector contact element and mating connector contact element, the temperature is determined indirectly through electrical parameters rather than direct thermal sensing, thus achieving faster response and higher precision without adding mechanical complexity
Solution Approach 2:
The patent introduces an intermediary measurement approach by using potential difference as a mediator between the contact point temperature and the measurement system. Instead of directly measuring temperature, the system measures electrical potential difference which correlates with temperature, providing an indirect but more accurate and faster measurement method
2Device complexity
If indirect temperature measurement is used with a temperature sensor located close to the contact point, then the device complexity is reduced, but the reliability deteriorates due to degradation of contact point
Solution Approach 1:
The patent introduces an intermediary measurement approach by using potential difference as a mediator between the contact point temperature and the measurement system. Instead of directly measuring temperature, the system measures electrical potential difference which correlates with temperature, providing an indirect but more accurate and faster measurement method
Solution Approach 2:
The patent replaces the mechanical/thermal measurement system (temperature sensor physically contacting or near the contact point) with an electrical measurement system. By measuring the potential difference between the connector contact element and mating connector contact element, the temperature is determined indirectly through electrical parameters rather than direct thermal sensing, thus achieving faster response and higher precision without adding mechanical complexity
3Measurement precision
If direct temperature measurement at the contact point is implemented, then the measurement precision and response speed improve, but the device complexity increases
Solution Approach 1:
The patent applies multi-functionality by using the existing electrical contact elements (connector contact element and mating connector contact element) for dual purposes: both for power transmission and for temperature measurement. The potential difference measurement utilizes the same electrical pathway that carries the main current, eliminating the need for separate temperature sensing hardware and reducing overall device complexity
Solution Approach 2:
The patent replaces the mechanical/thermal measurement system (temperature sensor physically contacting or near the contact point) with an electrical measurement system. By measuring the potential difference between the connector contact element and mating connector contact element, the temperature is determined indirectly through electrical parameters rather than direct thermal sensing, thus achieving faster response and higher precision without adding mechanical complexity
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 quick and accurate detection of overtemperature at the contact point, preventing damage by allowing for immediate intervention in power transmission, thus ensuring the reliability and longevity of both connectors and charging infrastructure.
Implementation Method 1
a connector potential at the connector contact element and/or a mating connector potential of the mating connector contact element can be determined. From the potential difference, the temperature at the contact point can be determined directly.
Data Source
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AI summary
This document relates to a connector (100) for determining a temperature (Tcontact) of a contact point. The connector (100) comprises a connector contact element (110, 110') for electrically contacting the connector (100) with a mating connector contact element (210) of a mating connector (200) at the contact point. Furthermore, the connector comprises a connector tap (160, 160') for tapping a connector potential (V1) at the connector contact element (110, 110') and a mating connector contact probe (170, 170') for determining a mating connector potential (V2) of the mating connector contact element (210). Thus, it is possible to determine the temperature (Tcontact) of the contact point from a potential difference (U) between the connector potential (V1) and the mating connector potential (V2).