Liquid-Cooled EV Charging Cable Cold-Start Pressure Control
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Solution Overview
Problem
Electric vehicle charging stations face issues during extreme cold conditions where the liquid in the liquid cooled charging cables can freeze or become viscous, leading to increased pressure and potential component failure if pumped at regular operating capacity.
Innovation Solution
A startup sequence is implemented that iteratively increases the speed of the pump and measures pressure until it reaches normal capacity, using a heat exchanger to manage temperature and antifreeze liquid, and includes sensors to monitor current and pressure, ensuring safe operation by preventing damage to components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pump operates at regular operating capacity in extreme cold conditions, then the charging station can provide full charging service, but the liquid in the cooling cable can freeze or become viscous leading to increased pressure and potential component failure
Solution Approach 1:
The system performs preliminary actions by gradually increasing pump speed from low to high in iterative steps before reaching full operating capacity. This preliminary gradual warming prevents the liquid from freezing or becoming overly viscous, allowing the system to then operate at full capacity safely without causing pressure buildup or component failure.
2Reliability
If the pump speed is increased gradually through iterative operations, then pressure buildup is prevented and component damage is avoided, but the time required to reach normal charging capacity is extended
Solution Approach 1:
The system uses feedback by continuously monitoring pressure levels during pump operation. Based on this feedback, the controller adjusts the pump speed iteratively - increasing speed when pressure is acceptable and maintaining or reducing speed when pressure approaches thresholds. This feedback mechanism optimizes the balance between reaching full capacity quickly and preventing component damage.
3Productivity
If the liquid is pumped at full capacity immediately during cold start, then charging service is provided without delay, but pressure increases and components may fail
Solution Approach 1:
The system applies dynamics by making the pump speed variable rather than fixed. The pump speed dynamically adjusts based on real-time pressure conditions and temperature considerations. During cold start, speed increases iteratively from low to high; during normal operation, it maintains full capacity. This dynamic adjustment prevents pressure buildup during cold starts while enabling full productivity during favorable conditions.
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 allows electric vehicle charging stations to safely operate during extreme cold by preventing pressure buildup and component failure, ensuring reliable charging by gradually increasing pump speed and managing temperature effectively.
Implementation Method 1
The charging station includes a heat exchanger that transfers heat from the warm side of the cooling loop
Implementation Method 2
The charging station includes a pump to pump a cool side of the liquid through the cooling loop
Data Source
AI summary
An electric vehicle charging station that uses a liquid cooled charging cable is described. The charging station includes a charging port that is configured to connect to a liquid cooled charging cable. The liquid cooled charging cable includes a cooling loop where a return side of the cooling loop is a warm side. The charging station includes a heat exchanger that transfers heat from the warm side of the cooling loop. The charging station includes a pump to pump a cool side of the liquid through the cooling loop. The charging station includes a module that causes the following to be performed in response to a startup sequence of the electric vehicle charging station: iteratively perform operations of operating the pump at increasing speeds and measuring corresponding pressure output until the speed of the pump is at its normal capacity.