Charging Cable Thermal Control for Electric Vehicles
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Solution Overview
Problem
Charging cables for electric propulsion vehicles often experience abnormal heat generation due to incomplete connections or tracking phenomena, leading to premature termination of charging sessions, which limits the duration of charging and fails to ensure a full charge by morning.
Innovation Solution
A charging cable equipped with a temperature detection unit and a control unit that monitors temperature and adjusts the conduction current by stopping and resuming power supply based on specified temperature thresholds, preventing damage and ensuring extended charging periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charging cable stops power supply when temperature exceeds a predetermined value, then abnormal heat generation is prevented, but charging period is shortened
Solution Approach 1:
The charging cable dynamically adjusts the power supply state based on real-time temperature monitoring. When temperature exceeds the first threshold, power supply is stopped to prevent overheating. When temperature drops below the second threshold, power supply is automatically resumed, creating a dynamic on-off control system that adapts to changing thermal conditions throughout the charging period
Solution Approach 2:
The charging process implements periodic interruption and resumption of power supply based on temperature cycles. The control unit periodically monitors temperature and creates periodic on-off patterns in power delivery, allowing the system to operate in cycles of charging and cooling rather than continuous or completely stopped operation
2Reliability
If charging is terminated when abnormal heat generation occurs, then safety is ensured, but charging demand cannot be satisfied
Solution Approach 1:
The temperature threshold mechanism converts the harmful effect of overheating into a beneficial control signal. By detecting temperature excursions and using them to trigger controlled power interruptions, the system transforms potential damage into a protective feedback mechanism that ultimately enables longer safe operation
Solution Approach 2:
The control unit continuously monitors temperature and uses this feedback to adjust power supply decisions. The feedback loop compares real-time temperature readings against predetermined thresholds and automatically adjusts the charging state, creating a self-regulating system that maintains safety while maximizing charging duration
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 prevents damage from abnormal heat and ensures a long charging period, allowing the battery to be fully charged by morning, even when temporary temperature spikes occur, thereby meeting the demand for prolonged charging.
Implementation Method 1
a temperature sensor that senses the temperature of the power plug
Implementation Method 2
abnormal heat generation caused by an incomplete connection between the electric outlet and the power plug or a tracking phenomenon
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A temperature detection unit (14a) detects the temperature of a power plug (14). A control unit (20a) stops electric conduction to a battery (6) when the detected temperature detected by the temperature detection unit (14a) is equal to or higher than a predetermined specified temperature (T1). The control unit (20a) recovers the electric conduction to the battery (6) when the detected temperature detected by the temperature detection unit (14a) decreases to a specified temperature (T2) or lower, the specified temperature (T2) being lower than the specified temperature (T1).