EV Charging Current Control for Connector Overheating
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Solution Overview
Problem
Current electric vehicle charging systems face safety risks due to abnormal heating at the charging connector contact node, leading to interrupted charging when temperature exceeds protection thresholds, failing to ensure full charge completion.
Innovation Solution
A method and device that control the charging current by sampling the temperature at the connector node, generating a current regulation amount to maintain the temperature near a target threshold, and adjusting the charging current to prevent overheating, allowing continuous high-power charging while ensuring safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charger cuts off the charging current when the temperature exceeds the protection threshold, then the safety of the charging connection node is improved, but the charging continuity is deteriorated
Solution Approach 1:
The patent implements a temperature feedback control mechanism where the charger continuously monitors the temperature of the charging connection node and dynamically adjusts the charging current accordingly. When the temperature approaches the protection threshold, the charger reduces the charging current to maintain temperature below the threshold, thereby preventing safety issues while avoiding complete charging interruption. This feedback loop enables continuous charging operation under temperature constraints.
Solution Approach 2:
The patent transforms the static temperature protection approach (binary on/off control) into a dynamic control system where the charging current is continuously adjusted based on real-time temperature conditions. The charger adapts the charging parameters dynamically to maintain operation within safe temperature limits, enabling continuous charging rather than intermittent operation with complete shutdowns.
2Productivity
If the charging current is increased to enable high-power charging, then the charging speed is improved, but the temperature of the charging connection node is deteriorated
Solution Approach 1:
The patent dynamically changes the charging current parameter based on the measured temperature of the charging connection node. When temperature is low, higher charging current is permitted for fast charging. As temperature approaches the protection threshold, the charging current is reduced to maintain safe operating conditions. This parameter adjustment strategy enables high-power charging when conditions permit while preventing overheating.
Solution Approach 2:
The temperature monitoring and charging current adjustment mechanism creates a feedback control system that balances charging speed and temperature control. The system continuously measures temperature and adjusts charging parameters in real-time, allowing the charger to operate at high power when safe and reduce power when temperature constraints are approached, thereby optimizing both charging speed and thermal management.
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 stabilizes the temperature at the charging connector node, enabling continuous charging without interruption, ensuring the electric vehicle is fully charged while preventing overheating and ensuring user safety.
Implementation Method 1
a temperature detecting unit coupled to the charging connector for sampling current temperature of a charging connection node where the charging connector is connected to the power supply or the electric vehicle
Implementation Method 2
The above factors lead to an increasing resistance at the contact node of the charging connector, so that high temperature is easily generated in charging process
Data Source
AI summary
The disclosure provides a method for controlling a charging current of an electric vehicle and a charging device. The controlling method includes: sampling current temperature of the charging connection node; generating a current regulation amount according to the current temperature and a preset target temperature threshold; and regulating the charging current flowing through the charging connection node according to the current regulation amount.