E-Bike Charging Cable Code Verification for Wrong-Cable Prevention
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Solution Overview
Problem
The variability in battery charging voltage among different manufacturers and brands of electric and electrically assisted bicycles poses a risk of electrocution and equipment damage due to incorrect cable connections, as users often connect the wrong cable or incorrectly connect the cable to the charger.
Innovation Solution
A cable with a generation circuit that sends a specific connection code to the charging station only when the correct voltage is detected, preventing the charging station from sending a charging current if an incorrect cable is used, thus ensuring safe and proper charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If users connect cables to charging stations without verification, then charging operation is simple and fast, but safety risks increase due to incorrect cable connections
Solution Approach 1:
The system performs preliminary verification by detecting the cable connection code before allowing charging current to flow. The charging station reads the code on connection conductors, verifies it matches the expected value, and only then activates the charging process. This preliminary action prevents incorrect cable connections from causing safety hazards while maintaining ease of operation for users with correct cables.
Solution Approach 2:
Connection conductors serve as an intermediary verification mechanism between the cable and charging current. These dedicated conductors carry identification codes that act as a mediator, allowing the charging station to verify cable compatibility before establishing the main charging connection. This intermediary layer enables safety verification without complicating the user interface.
2Productivity
If charging station sends charging current without code verification, then charging process is efficient, but equipment damage risk increases
Solution Approach 1:
The charging station performs preliminary code verification through dedicated detection conductors before activating the charging current. The control unit reads the connection code, compares it against expected values, and only permits charging current flow when verification succeeds. This preliminary verification ensures equipment safety while maintaining charging efficiency for properly connected cables.
Solution Approach 2:
The system implements feedback control by continuously monitoring the connection code and using this information to control charging current delivery. The charging station reads the code, verifies its validity, and provides feedback by either enabling or disabling the charging current accordingly. This feedback mechanism ensures reliability without significantly impacting charging productivity for correct connections.
3Reliability
If cable includes code generation circuit and multiple conductors, then connection verification reliability improves, but cable complexity increases
Solution Approach 1:
The cable structure is segmented into distinct functional components: power conductors for charging current, separate connection conductors for code transmission, and a generation circuit for producing the identification code. This segmentation allows each component to perform its specific function reliably while keeping the overall design manageable through clear functional separation.
Solution Approach 2:
The connection conductors serve multiple functions: they transmit the identification code from the cable to the charging station, and also serve as part of the electrical connection path. This multi-functionality reduces the need for entirely separate verification wiring, thereby limiting the increase in cable complexity while maintaining verification reliability.
Data Source
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AI summary
The present invention relates to a cable (100) comprising a connector (101) for connection to a charging station (1), a connector (102) for connection to a battery (200) for charging an electric (2) or electrically assisted bicycle, and charging current conductors (103). According to the invention, the cable (100) comprises a generation circuit (106) with a permanent memory (108) in which a prescribed connection code (107) is stored, and two electrical code communication conductors (109) connected to two communication ends (110) present in the connector (101). The generation circuit (106) is configured to send the prescribed connection code (107) to the electrical code communication conductors (109) when the electrical voltage detector (1120) detects that a prescribed electrical voltage (114) is present between two electrical voltage detection conductors (111).