EV Charging Connector Temperature Difference Control
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Solution Overview
Problem
Heat generation in electric vehicle charging plugs poses a risk of damage and injury, and existing temperature measurement methods are too slow to serve as an effective safety mechanism for controlling charging currents.
Innovation Solution
The implementation of a temperature sensor system in electric vehicle charging systems that measures temperature differences across various points in the cooling circuit to control charge current, allowing for real-time adjustments to prevent overheating and detect potential cooling unit failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active liquid cooling with temperature control loops is used, then heat dissipation performance is improved, but the response speed of temperature measurement is too slow to serve as an effective safety mechanism
Solution Approach 1:
The system divides the temperature monitoring function into two independent parts: a slow temperature control loop for optimization and a fast temperature difference measurement loop for safety. Multiple temperature sensors are distributed at different positions (inlet, outlet, and intermediate points) to enable localized temperature difference measurements that respond quickly to thermal events without requiring full thermal equilibrium.
Solution Approach 2:
The patent uses temperature difference (ΔT) as an intermediary parameter between the cooling system state and safety control. Instead of directly controlling or monitoring absolute temperatures with slow response, the system measures temperature differences between adjacent sensor points, which provides a faster responding proxy indicator of thermal conditions and cooling effectiveness.
2Measurement precision
If multiple temperature sensors are used to monitor critical positions, then temperature measurement accuracy is improved, but the complexity of the control system increases
Solution Approach 1:
The patent extracts the safety-critical function from the complex temperature control system by using only temperature difference measurements between sensor pairs. This simplified approach focuses monitoring on the essential safety parameter (temperature gradient indicating potential overheating) rather than attempting to control or monitor all absolute temperature points, reducing control complexity while maintaining measurement precision for safety purposes.
3Temperature
If liquid cooling tubes are routed along the cable into the plug, then heat dissipation capability is improved, but the risk of damage and injury from heat generation remains
Solution Approach 1:
The system performs preliminary safety assessment by continuously measuring temperature differences between sensor points before critical overheating can occur. The fast-response ΔT measurement enables the system to detect emerging thermal problems early and trigger protective actions (current reduction or shutdown) before temperatures reach dangerous levels that could cause damage or injury.
Solution Approach 2:
The patent implements a safety feedback mechanism where temperature difference measurements directly influence charging current control. When temperature differences exceed predetermined thresholds, the system automatically reduces or terminates charging current, creating a closed-loop safety feedback that actively prevents harmful temperature conditions despite the presence of liquid cooling tubes.
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 solution provides a failsafe mechanism to prevent overheating by dynamically controlling charge current based on temperature differences, ensuring the safety and reliability of the charging process by quickly detecting and responding to cooling unit defects or inefficiencies.
Implementation Method 1
a plurality of temperature sensors attached to the cooling circuit at different positions and providing measured temperatures to the control unit
Implementation Method 2
One common device to remove heat is active liquid cooling, where liquid-filled tubes are routed along the cables and into the plug
Implementation Method 3
the temperature of the cooling liquid in the cable is controlled in a control loop, and modulated by changing the current through the charge cable, which is also known as de-rating
Data Source
AI summary
A system and method for using an electric vehicle (EV) charging system that includes an EV charger, a current control unit, a charge connector, a charge cable connecting the EV charger with the charge connector, a cooling circuit, and a plurality of temperature sensors attached to the cooling circuit at different positions and providing measured temperatures to the control unit includes operating the control unit to control charge current in dependence on temperature differences measured between temperature sensors of the plurality of temperature sensors.