Electric Cable With Coolant Line And Conductive Sensing
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Solution Overview
Problem
Charging cables for electric vehicles face operational hazards due to coolant leakage, which can compromise insulation and safety when electrically conductive coolants like water escape, and existing solutions either increase cable weight or flexibility issues.
Innovation Solution
Incorporating at least one electrically conductive sensing line within the cable hose that detects changes in electrical conductivity to identify coolant leakage, allowing for real-time monitoring and potential interruption of the charging process if leakage is detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cross-section of the load conductor is increased to counteract heating, then the cable's heat dissipation capability is improved, but the cable becomes heavier and less flexible
Solution Approach 1:
A coolant line is introduced as an intermediary element within the cable structure to carry coolant that actively removes heat from the load conductor. This mediator allows heat dissipation without increasing conductor cross-section, thereby avoiding increased weight while maintaining flexibility.
Solution Approach 2:
The patent employs hydraulic cooling by routing a liquid coolant through dedicated coolant lines surrounding the load conductor. The coolant absorbs heat through convection and carries it away, enabling effective heat dissipation without requiring larger conductor dimensions, thus avoiding weight increase and flexibility loss.
2Temperature
If coolant lines are added to cool the cable, then heat dissipation is improved, but the risk of coolant leakage and insulation compromise increases
Solution Approach 1:
Sensing lines are installed within the cable structure to detect coolant leakage before it can compromise the insulation or reach high-voltage components. This preliminary detection allows for early warning and preventive action, maintaining reliability while enabling effective cooling through coolant lines.
Solution Approach 2:
The sensing lines provide continuous feedback about the coolant's condition and position within the cable. When coolant leakage is detected, the system can respond by alerting operators or shutting down cooling, thereby preventing insulation compromise while maintaining the heat dissipation benefits of the coolant system.
3Reliability
If sensing lines are added to detect coolant leakage, then safety monitoring is improved, but the cable structure becomes more complex
Solution Approach 1:
The sensing lines utilize the coolant itself as the detection medium. The coolant's electrical conductivity or other physical properties are monitored directly, allowing the system to self-diagnose leakage conditions without requiring external monitoring equipment. This approach improves reliability while minimizing additional structural complexity.
Solution Approach 2:
The sensing lines serve multiple functions: they detect coolant leakage, monitor coolant position, and can potentially measure temperature gradients. This multi-functionality improves reliability for coolant leakage detection while reducing the need for separate monitoring systems, thereby limiting the increase in structural 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
The solution effectively reduces operational hazards by enabling early detection of coolant leakage, ensuring safety and maintaining cable flexibility without excessive weight increase, thus preventing insulation compromise and ensuring reliable charging operations.
Implementation Method 1
at least one electrically conductive sensing line extending within the cable conduit, which is at least partially not electrically insulated, for detecting a measurement signal indicating a change in the electrical conductivity in the cable conduit
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a cable (2) for transferring an electric current, which cable comprises a cable sleeve (20), at least one electric load line (22) extended in the cable sleeve (20) for conducting an electric current, and at least one extended cooling line (23, 24) in the cable sleeve (20) for carrying a coolant. In addition, at least one extended electrically conductive sensing line (25, 26), which is not electrically insulated, at least in some sections, is provided in the cable sleeve (20) to detect a measuring signal indicating a change in the electrical conductivity in the cable sleeve (20). In this way, a cable for carrying an electric current is provided, by means of which a hazard in the event of coolant emerging from the extended coolant line in the cable sleeve can at least be reduced.