Inspection Connector for EV Charging Function Verification
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Solution Overview
Problem
Current charging function inspection methods for electric vehicles in production lines are costly, time-consuming, and labor-intensive, requiring significant infrastructure and safety installations, and are inefficient due to the weight and complexity of charging guns and cables.
Innovation Solution
A charging function inspection device with an inspection connector and controller that communicates with the vehicle to determine the normalcy of charging functions, allowing for quick and slow charging inspections through a single connection, reducing the need for high-voltage substations and improving operator convenience by integrating quick and slow charging capabilities into a single inspection connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If actual charging inspection is performed using charging guns and cables in the production line, then charging function normalcy can be determined, but inspection cost and time increase significantly
Solution Approach 1:
The patent creates a simplified copy of the charging inspection function using an inspection connector that simulates charging gun connectivity without requiring actual charging equipment. The inspection connector replicates the essential electrical connection and communication protocols needed to verify charging function normalcy, eliminating the need for time-consuming actual charging cycles while maintaining inspection reliability
Solution Approach 2:
The inspection connector serves as an intermediary device between the vehicle's charging port and the inspection system. It mediates the inspection process by providing a direct electrical connection that allows the control unit to communicate with the vehicle's battery management system and determine charging function normalcy without requiring actual charging guns, cables, or high-voltage substations
2Reliability
If charging inspection is performed using actual charging guns and cables, then charging function can be inspected, but operator convenience deteriorates due to weight and complexity
Solution Approach 1:
The patent extracts the essential inspection function from the complex charging gun and cable system. By removing the need for heavy charging equipment and using only a lightweight inspection connector, the solution maintains charging function inspection capability while dramatically improving operator convenience through reduced weight and simplified operation
Solution Approach 2:
The inspection connector is designed as a simple, lightweight, single-use or limited-use component that replaces expensive and heavy charging guns. This disposable or limited-life connector provides all necessary inspection functions without the complexity and weight of professional charging equipment, making operation significantly easier for production line workers
3Reliability
If high-voltage substations are installed in the production line for charging inspection, then charging function inspection can be performed, but infrastructure cost increases
Solution Approach 1:
The patent extracts the inspection capability from the expensive high-voltage substation infrastructure by using the vehicle's existing battery management system and communication protocols. The inspection connector directly interfaces with the vehicle's charging port and communicates with its control units, eliminating the need for external high-voltage power supply equipment while maintaining full inspection capability
Solution Approach 2:
The inspection system utilizes the vehicle's own battery management system and communication interfaces to perform self-inspection. The vehicle's control units provide charging status information and respond to inspection commands without requiring external high-voltage substations, making the inspection process infrastructure-independent and significantly reducing manufacturing complexity
Data Source
AI summary
A charging function inspection device for eco-friendly vehicles is provided. The charging function inspection device includes an inspection connector connectable to a vehicle to supply a communication signal and a power signal to the vehicle, and an inspection controller configured to determine whether a charging function of a high-voltage battery of the vehicle is operated normally based on the connection of the inspection connector.