EV Battery Discharge Control via Connector Thermistor

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Solution Overview

Problem

Existing electric vehicle battery charging systems lack effective mechanisms to determine whether to discharge the battery safely based on connector connection status and temperature, potentially leading to accidents due to overtemperature or improper power supply.

Innovation Solution

An electric battery charging system incorporating a thermistor element with a negative temperature coefficient, a micro control unit, and a vehicle charging management system that determines discharge based on connector connection and temperature, utilizing a bimetal switch and LED for safety, and sealing the thermistor to prevent moisture ingress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the battery discharge function is added to increase energy utilization, then the versatility of the electric vehicle is improved, but the risk of overtemperature and safety accidents increases

Engineering Contradiction:

Improveenergy utilizationVSAvoidovertemperature risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary temperature detection and connector connection status verification before allowing battery discharge. The thermistor element continuously monitors temperature, and the control unit prevents discharge operation until proper connection is confirmed, thereby preventing overtemperature and safety accidents before they can occur

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements real-time feedback through the thermistor element that continuously monitors connector temperature during battery discharge. When the temperature exceeds the predetermined threshold, the control unit receives this feedback signal and immediately stops the discharge operation, preventing overtemperature conditions

Inventive Principle:

Principle #23Feedback

2Reliability

If temperature detection and connection verification mechanisms are added to ensure safety, then the reliability of the battery discharge function is improved, but the device complexity increases

Engineering Contradiction:

Improvedischarge safetyVSAvoidsystem structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control unit is designed to perform multiple functions: it controls the relay for battery discharge, monitors thermistor temperature signals, verifies connector connection status, and manages LED indicators. By integrating these diverse functions into a single control unit, the system achieves high reliability without proportionally increasing overall system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the temperature detection function and connection verification function into a unified control system. The thermistor element is integrated with the connector, and both sensors feed into the same control unit that manages the relay and LED indicators, thereby reducing the number of separate components and simplifying the overall system structure

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the thermistor element is sealed to prevent moisture ingress and improve reliability, then the durability of the temperature sensor is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvesensor durabilityVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The thermistor element is nested within the connector structure and sealed inside a protective housing. This nested design protects the sensitive temperature sensor from moisture and environmental damage while maintaining a compact form factor that simplifies integration into the overall connector assembly

Inventive Principle:

Principle #7Nested doll (Nesting)

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

Ensures safe battery discharge by preventing overtemperature conditions and maintaining connector stability, reducing the risk of accidents and ensuring reliable power supply to external devices.

Implementation Method 1

a thermistor element configured to change a resistance value according to a temperature; The thermistor element includes a negative temperature coefficient (NTC) thermistor element

Methodology Applied

Scientific EffectNegative temperature coefficient (NTC) thermistor effect: Thermistor

Implementation Method 2

a bimetal switch configured to cut off power according to the temperature of the connector

Methodology Applied

Scientific EffectBimetallic strip effect: Bi-Metallic Strip

Data Source

PatentUS20230127745A1Electric battery charging system, control method thereof, and vehicle with electric battery charging system

Publication Date: 2023.04.27 HYUNDAI MOTOR CO LTD

AI summary

Provided is an electric battery charging system, including a connector including a thermistor element configured to change a resistance value according to a temperature, a micro control unit (MCU) configured to receive a voltage varying depending on whether the connector is connected, and receive a voltage varying according to the resistance value of the thermistor element, and a vehicle charging management system (VCMS) configured to determine whether to discharge a battery based on whether the connector is connected and a temperature of the connector.