EV Charging Connector With DC Power Regulation and Feedback
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Solution Overview
Problem
Electric vehicles face challenges with poor energy storage and long recharging times due to limitations in current charging technologies, which affect their range and operational efficiency.
Innovation Solution
A connector system with a coupling mechanism, direct current conductors, and a power supply circuit that regulates power delivery to electric vehicles, including communication controllers to manage charging data and monitor recharging processes, ensuring safe and efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If current charging technologies are used, then electric vehicles can be charged, but recharging times are long and energy storage is poor
Solution Approach 1:
The patent changes the electrical parameters by using direct current (DC) conductors to supply DC power directly to the battery, bypassing the need for AC-to-DC conversion within the vehicle. The power supply circuit regulates voltage and current parameters to enable faster charging while maintaining safety. This parameter change allows higher power delivery rates that reduce recharging time without compromising battery integrity.
Solution Approach 2:
The connector system performs preliminary actions by pre-regulating and preparing the power output before connection to the vehicle. The power supply circuit pre-adjusts voltage and current to optimal charging levels, and the coupling mechanism ensures proper alignment and connection before full power transfer begins. This preliminary preparation enables immediate high-efficiency charging upon connection, minimizing idle time.
2Productivity
If higher power delivery is used to reduce charging time, then recharging speed increases, but safety risks may increase
Solution Approach 1:
The power supply circuit incorporates feedback mechanisms that continuously monitor charging parameters such as voltage, current, and temperature. The communication controller exchanges data between the connector and vehicle battery management system, allowing real-time adjustment of power delivery based on battery state of charge, temperature conditions, and accepted charging rates. This feedback loop enables high-speed charging while automatically reducing power if safety thresholds are approached, maintaining both speed and safety.
Solution Approach 2:
The system implements beforehand cushioning through multiple protective measures built into the connector design. The coupling mechanism includes mechanical and electrical interlocks that prevent improper connection. The power supply circuit includes over-voltage, over-current, and short-circuit protection that activates before dangerous conditions can develop. These preemptive safety features allow the system to operate at high power levels with confidence that safety margins are maintained.
3Ease of manufacture
If a simple connector design is used, then ease of manufacture increases, but power regulation and monitoring capabilities are insufficient
Solution Approach 1:
The patent merges multiple functions into the connector assembly: the coupling mechanism provides mechanical connection and alignment, the DC conductors provide power transfer, the power supply circuit provides voltage and current regulation, and the communication controller provides data exchange and monitoring. By combining these previously separate components into an integrated connector system, the invention achieves advanced power regulation and monitoring capabilities while maintaining a unified, manufacturable design. The integration reduces the number of separate assemblies needed and simplifies the overall manufacturing process.
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 system enables efficient and safe charging of electric vehicles by regulating power delivery and monitoring recharging processes, addressing the limitations of current charging technologies and enhancing the operational efficiency and range of electric vehicles.
Implementation Method 1
A connector includes at least a direct current conductor. At least a direct current conductor is configured to supply a direct current to an electric vehicle.
Implementation Method 2
A connector includes a power supply circuit. A power supply circuit is configured to regulate a direct current supplied to an electric vehicle as a function of a power threshold.
Data Source
AI summary
In an aspect a connector for charging an electric vehicle. A connector includes a coupling mechanism. A coupling mechanism is configured to mate with an electric vehicle port of an electric vehicle. A coupling mechanism includes a fastener for removable attachment with an electric vehicle port. A connector includes at least a direct current conductor. At least a direct current conductor is configured to supply a direct current to an electric vehicle. A connector includes a power supply circuit. A power supply circuit is configured to regulate a direct current supplied to an electric vehicle as a function of a power threshold.