Thermal Sensing System for Electric Vehicle Charging Contacts
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Solution Overview
Problem
Existing thermal sensing systems for electrical contacts in electric vehicle charging devices are inaccurate and have delayed response times due to their distance from the electrical power contacts, leading to limited control over charging operations and potential heat-related damage or fires.
Innovation Solution
A thermal sensing system that converts electrical contact heat into mechanical energy, using a movable sensing feature coupled to the contact, which is detected by a non-contact position sensor to monitor temperature changes, allowing for timely and accurate temperature monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are positioned far away from electrical power contacts to prevent electrical interference, then electrical isolation is improved, but temperature measurement accuracy and response time deteriorate
Solution Approach 1:
The patent introduces a channel structure that serves as an intermediary pathway, allowing the temperature sensing element to physically access the electrical contact surface while maintaining electrical isolation through the channel walls. This mediator enables thermal contact without electrical interference.
Solution Approach 2:
The patent replaces direct electrical contact-based temperature sensing with a mechanical/thermal conduction approach through the channel structure. The sensing element conducts heat mechanically through the channel to measure temperature, substituting the need for electrical proximity.
2Measurement precision
If temperature sensors are positioned close to electrical power contacts to improve temperature monitoring accuracy, then temperature measurement precision is improved, but electrical interference and arcing worsen
Solution Approach 1:
The channel structure acts as an intermediary barrier that allows thermal energy to pass through while blocking electrical interference and arcing. The sensing element positioned within the channel can monitor temperature closely without being exposed to harmful electrical effects.
Solution Approach 2:
The channel walls function as a protective shell or barrier that separates the sensing element from the electrical contact surface, allowing thermal conduction while preventing electrical contact and interference.
3Productivity
If power transfer rate is increased to reduce charging duration, then productivity is improved, but heat generation and safety risks worsen
Solution Approach 1:
The temperature sensing system provides real-time feedback on the thermal state of electrical contacts during high-power charging operations. This feedback enables the control system to monitor temperature continuously and take corrective action before dangerous heat levels are reached, allowing safer operation at higher power levels.
Solution Approach 2:
The temperature sensing element is positioned within the channel structure in advance, ready to detect temperature changes before they become dangerous. This preliminary positioning enables early detection and preventive action to avoid heat-related damage during high-power charging.
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 system provides enhanced accuracy and responsiveness in monitoring electrical contact temperatures, enabling better control over charging operations to prevent heat damage and fires, improving safety and efficiency.
Implementation Method 1
a temperature sensing element disposed at least partially outside of an opening of the channel. The temperature sensing element is configured to move relative to the electrical contact from a first position to a second position in response to a temperature within the channel exceeding a designated threshold temperature
Data Source
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AI summary
A thermal sensing system (100) includes an electrical contact (102), a sensing element (104), and at least one position sensor (106). The electrical contact releasably connects to a mating contact (112) for establishing a conductive path across a mating interface. The electrical contact defines a channel (136) therein that extends from an opening (138) along an outer surface (140) of the electrical contact. The sensing element is at least partially outside of the channel and is configured to move relative to the electrical contact from a first position to a second position based on a temperature increase within the channel that exceeds a designated threshold temperature. The at least one position sensor is spaced apart from the electrical contact and is configured to detect a position change of the sensing element from the first position to the second position, indicating that the temperature within the channel exceeds the designated threshold temperature.