Cooled Charging Cable Leak Detection Using Coolant Voltage Monitoring
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Solution Overview
Problem
High current charging equipment for electric vehicles generates excessive heat, which can lead to coolant fluid leaks from cooling conduits coming into contact with electrical conductors, causing damage to the cable and charging equipment.
Innovation Solution
A cable assembly with a leak detection module that includes a power source to generate an input voltage signal applied at a node contacting the coolant fluid, and a controller to monitor output voltage changes and detect leaks, alerting users or automatically stopping power supply to prevent faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the cross section of the current carrying conductor is increased to reduce heat loss, then heat loss is reduced, but the cable becomes difficult to handle
Solution Approach 1:
A cooling conduit is introduced as an intermediary component that carries coolant fluid through the cable assembly. This mediator removes heat from the conductors through thermal exchange with the flowing coolant, enabling the cable to handle high currents without requiring an oversized conductor cross-section, thus maintaining flexibility and ease of handling.
2Temperature
If a cooling conduit is added to carry coolant fluid, then heat removal capability is improved, but the risk of fluid leakage and contact with electrical conductors increases
Solution Approach 1:
A leak detection module is integrated into the cable assembly to continuously monitor the integrity of the cooling conduit. This preliminary detection system identifies fluid leaks before they can contact electrical conductors and cause damage. Upon detecting a leak, the system automatically shuts off power supply, preventing harmful effects.
3Productivity
If high current flow is used to decrease charging time, then charging speed is improved, but heat generation increases
Solution Approach 1:
The cooling conduit with flowing coolant acts as a thermal mediator between the high-current conductors and the environment. It absorbs excess heat generated during high-current fast charging and transports it away from the cable, enabling sustained high current operation without dangerous temperature rise, thus maintaining high charging speed safely.
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
The leak detection module effectively prevents damage by detecting fluid leaks and stopping power supply, ensuring safety and preventing faults in the cable assembly.
Implementation Method 1
The cooling conduit may carry a coolant fluid that can take away some or all of the heat generated in the conductors
Implementation Method 2
The cooling conduit is adapted to convey a fluid that cools the electric conductor
Implementation Method 3
the leak detection module includes a power source to generate an input voltage signal which is applied at a first node that contacts with the fluid. The leak detection module includes a controller to monitor an output voltage signal at the nodes and to detect a leak of the fluid from the cooling conduit based on changes detected from the output voltage signal
Data Source
AI summary
A cable assembly includes a cable having a first end and a second end. The cable has an electric conductor and a cooling conduit, each of which extends from the first end to the second end. The cooling conduit is adapted to convey a fluid that cools the electric conductor. The cable assembly includes a leak detection module to detect a leak of the fluid from the cooling conduit. The leak detection module includes a power source to generate an input voltage signal which is applied at a first node contact with the fluid. The leak detection module includes a controller to monitor an output voltage signal at the first node and to detect a leak of the fluid from the cooling conduit based on the output voltage signal.