Charging Cable Temperature Control for EV Fast Charging
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Solution Overview
Problem
Current fast charging systems for electric vehicles face challenges with the rigidity and handling of charging cables due to their weight and material properties, leading to difficulties in connecting and disconnecting the cables, especially in low temperatures, which affects user acceptance and efficiency.
Innovation Solution
A charging cable device with a temperature control system that includes fluid lines connected to a temperature control device, heating the cable to reduce its rigidity and improve flexibility, allowing easier handling by pre-heating the cable before use and cooling it during charging to manage line losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the charging cable uses thick conductors and robust cable sheath to handle high power levels, then the power transmission capability is improved, but the cable weight and rigidity increase, making it difficult to handle
Solution Approach 1:
The patent applies parameter changes by heating the charging cable to change its physical state. The heating device increases the temperature of the cable, which reduces the rigidity of the conductor material and insulation layer, making the cable more flexible and easier to handle despite its thick construction required for high power transmission.
Solution Approach 2:
The patent replaces mechanical handling efforts with a thermal system. Instead of relying on manual strength to bend and position the rigid heavy cable, a heating device is used to thermally soften the cable materials, substituting mechanical force with thermal energy to achieve flexibility.
2Ease of operation
If the charging cable is heated to improve flexibility, then the ease of operation is improved, but the energy loss increases
Solution Approach 1:
The patent applies preliminary action by heating the charging cable before the charging process begins. The heating device pre-heats the cable to improve its flexibility for connection, and the control unit manages the heating timing so that it occurs before charging starts, minimizing the duration of energy loss.
Solution Approach 2:
The patent uses periodic action through the control unit that activates the heating device only when needed (before charging) and deactivates it during charging. This periodic on-off control reduces continuous energy consumption while maintaining cable flexibility when required.
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 heating and cooling system enhances the flexibility and handling of the charging cable, reducing user fatigue and improving the overall efficiency of the charging process by maintaining optimal cable temperature and flexibility, especially in low ambient conditions.
Implementation Method 1
a heating device (40) in order to heat the fluid
Implementation Method 2
The heating device is arranged in an inflow to the charging cable
Implementation Method 3
a cooling device (70) in order to cool the fluid in the fluid circuit
Data Source
AI summary
A charging cable device for a fast charging station for fast charging a battery of a vehicle with an electric drive, having a temperature control device, and a charging cable connected thereto. The charging cable has a multiplicity of fluid lines which extend from an end of the charging cable facing the temperature control device to an end facing away from the temperature control device, and are connected to one another at the end facing away from the temperature control device. The temperature control device is connected to the fluid lines of the charging cable to form a fluid circuit. The temperature control device is designed to heat a fluid in the fluid circuit. Also disclosed is a fast charging station for fast charging a battery of a vehicle with an electric drive. The fast charging station has a charging cable device at the top.