EV Charging Inlet Current Control with Cooling Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Plug-in charging of electric vehicles results in heat loss at the contact portion between the charging cable and vehicle inlet, leading to potential overheating, and existing solutions fail to balance charging time and component protection effectively due to mixed distribution of charging facilities with and without cooling mechanisms.
Innovation Solution
A vehicle system that determines whether a charging facility has a cooling mechanism and adjusts the maximum allowable current accordingly, setting higher currents when a cooling mechanism is present to shorten charging time while limiting currents when it is not to protect the charging cable and inlet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the charging power is increased to shorten charging time, then the charging time is reduced, but the heat loss at the contact portion increases causing potential overheating
Solution Approach 1:
The patent applies dynamics by making the maximum allowable current dynamic rather than fixed. The control device adjusts the maximum allowable current based on real-time temperature conditions at the contact portion, allowing higher currents when cooling is effective and lower currents when temperature rises, thus resolving the contradiction between charging speed and heat management
Solution Approach 2:
The patent changes the parameter of maximum allowable current based on the presence of cooling mechanisms and temperature conditions. When a cooling mechanism is detected, the system allows higher charging currents; when no cooling mechanism is present or temperature exceeds thresholds, the system reduces the current limit, thereby balancing charging time reduction with heat loss control
2Power
If a cooling mechanism is added to the charging facility, then the charging power can be increased safely, but the device complexity increases
Solution Approach 1:
The patent uses an intermediary approach by introducing a control device that detects the presence of cooling mechanisms and mediates the charging power accordingly. Instead of requiring all facilities to have cooling mechanisms, the system adapts the charging power based on whether cooling is available, thus achieving high power charging where possible without universally increasing device complexity
Solution Approach 2:
The control device provides multi-functionality by performing both temperature monitoring and charging power management. The system can operate with or without cooling mechanisms, adapting its behavior to different facility types, which makes the solution universally applicable without requiring additional cooling infrastructure at every charging location
3Loss of time
If the maximum allowable current is set high for facilities with cooling mechanisms, then charging time is shortened, but charging facilities without cooling mechanisms cannot be distinguished
Solution Approach 1:
The patent implements feedback by having the control device detect information about the charging facility's cooling mechanism presence and use this feedback to adjust the maximum allowable current. The system receives information from the charging facility about whether cooling mechanisms are present, and this feedback loop enables differentiated current settings that both shorten charging time when appropriate and prevent overheating when cooling is unavailable
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 allows for efficient charging time reduction while ensuring the safety and protection of charging components, by dynamically adjusting charging power based on the presence of a cooling mechanism in the charging facility.
Implementation Method 1
by a cooling mechanism in which a coolant circulates between the charging facility and the connector of the charging cable (the so-called water-cooled cooling mechanism), the connector of the charging cable and the inlet can be cooled
Implementation Method 2
Plug-in charging causes heat loss (Joule heat) in a portion of contact between the connector provided at the end of the charging cable and the inlet on the vehicle side
Data Source
AI summary
A vehicle is configured to perform plug-in charging for charging a battery mounted in the vehicle with electric power supplied through a charging cable from a charging stand. The vehicle includes: an inlet to which a connector of the charging cable is connectable; and an ECU configured to control a supply current from the charging stand such that the supply current does not exceed a maximum allowable current. The ECU is configured to obtain specific information as to whether or not the charging stand is provided with a cooling mechanism for cooling the connector and the inlet. The ECU is configured to set the maximum allowable current to be higher when the charging stand is provided with the cooling mechanism than when the charging stand is not provided with the cooling mechanism.