EV Charging Connector Thermal Management via Adaptive Current Control
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Solution Overview
Problem
Charging connection devices for electric vehicles face challenges in maintaining reliable operation and preventing overheating, which can lead to malfunctions or fires, especially under varying environmental conditions, while also ensuring efficient charging without excessive oversizing of components.
Innovation Solution
A method that uses temperature sensors to monitor internal temperatures, reducing the charging current when a first limit temperature is exceeded and aborting the charging process only when a second limit temperature is reached, with adjustable periods and tolerance values to balance reliability and efficiency, and includes ventilation for active cooling when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charging process is stopped immediately when a temperature limit is exceeded, then the reliability of the charging connection device is improved, but the productivity of the charging process deteriorates
Solution Approach 1:
The patent applies dynamics by making the charging current adjustable based on temperature conditions. Instead of a static on/off control, the system dynamically adapts the charging current level according to the measured temperature, allowing the charging process to continue at reduced power when temperatures are elevated but not critical, thus maintaining productivity while ensuring reliability
Solution Approach 2:
The patent changes the parameter of charging current based on temperature measurements. When the temperature exceeds a threshold but remains below a critical limit, the system reduces the charging current to a lower level rather than stopping completely. This parameter adjustment allows the charging process to continue at a reduced rate, balancing reliability concerns with productivity maintenance
2Temperature
If the maximum charging current is reduced to prevent overheating, then the temperature control is improved, but the charging efficiency deteriorates
Solution Approach 1:
The system dynamically adjusts the charging current based on real-time temperature measurements. When temperatures are within acceptable ranges, full charging current is permitted for maximum efficiency. When temperatures rise but remain below critical thresholds, the current is reduced to a lower level rather than stopped, maintaining a balance between temperature control and charging efficiency
Solution Approach 2:
The charging current parameter is changed based on temperature conditions. The system transitions between different current levels (full current, reduced current, or zero current) depending on the measured temperature, allowing efficient charging when conditions permit while preventing overheating when temperatures approach limits
3Reliability
If components are oversized to handle maximum temperature conditions, then the reliability under extreme conditions is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The system employs self-service through automatic temperature monitoring and adaptive current control. The temperature sensor continuously monitors internal temperatures, and the control unit automatically adjusts the charging current accordingly without requiring manual intervention or complex mechanical cooling systems. This intelligent self-regulation eliminates the need for oversized passive cooling components
Solution Approach 2:
The patent replaces mechanical or passive thermal management systems (such as large heat sinks, fans, or liquid cooling systems) with an electronic control system that actively manages temperature through adaptive current adjustment. This substitution of active electronic control for passive mechanical thermal management reduces device complexity and manufacturing costs while maintaining reliability
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
This approach enhances the availability and reliability of charging connection devices by preventing overheating while maintaining efficient charging, reducing power loss, and extending the service life of components, with minimal additional effort and efficient cooling.
Implementation Method 1
at least one temperature sensor continuously detecting at least one temperature value inside the housing
Implementation Method 2
heat, which, together with the thermal energy introduced by the environment (ambient air with a certain temperature, solar radiation, etc.), leads to heating of the charging connection device or its components
Implementation Method 3
Environmental conditions such as direct sunlight, ambient air temperature, air flow or any neighboring heat sources have a significant and changing influence on the heat dissipation from the housing
Data Source
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AI summary
The invention relates to a method for operating a charging connection device for electric vehicles, said charging connection device comprising a housing inside which at least one temperature sensor constantly senses at least one temperature value. As an essential feature, the maximum permissible charging current is reduced to a specific value greater than zero when the at least one temperature value exceeds a first threshold temperature (21), and the charging process is interrupted if the first threshold temperature (21) has been continuously exceeded by the end of a given first interval (22) or when the at least one temperature value exceeds a second threshold temperature (23) that is higher than the first threshold temperature (21). The proposed method for operating a charging connection device for electric vehicles provides for greater availability, better fault tolerance and operational reliability of the charging connection device while ensuring lower production costs.