EV Charging Device Over-Temperature Protection Circuit
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Solution Overview
Problem
Conventional electric vehicle charging devices often overheat due to high charging currents and improper connections, leading to potential damage or safety hazards.
Innovation Solution
A charging device equipped with a temperature detecting circuit and over-temperature protection circuit that reduces charging current and notifies the electric vehicle to initiate a protection procedure when threshold temperatures are exceeded, enhancing safety without requiring additional wiring and allowing for wireless communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large charging current is provided to shorten charging time, then charging speed is improved, but temperature of charging device increases
Solution Approach 1:
The patent implements a temperature detection feedback mechanism where a temperature detection circuit continuously monitors the temperature of the power plug and control box, and feeds this information back to the control unit. When temperature exceeds a threshold, the control unit automatically reduces or stops charging current, creating a closed-loop control system that balances charging speed with thermal safety.
Solution Approach 2:
The charging current is made dynamically adjustable based on real-time temperature conditions. The control unit can modify the charging current magnitude according to temperature feedback, transitioning between different charging states (normal charging, reduced current, or stopped charging) to prevent overheating while maximizing charging efficiency when conditions permit.
2Ease of operation
If improper connection between power socket and commercial AC power source, then connection convenience is improved, but heat generation and leakage current increase
Solution Approach 1:
The patent performs preliminary detection of connection status and temperature conditions before initiating full charging. The temperature detection circuit and connection confirmation circuit check the connection state in advance, and only when conditions are proper does the system allow normal charging to proceed, preventing harmful effects from improper connections.
Solution Approach 2:
The control unit acts as an intermediary between the power source and charging process. It mediates by continuously monitoring temperature and connection status, and based on these conditions, it controls the power transmission to either allow normal charging, reduce current, or stop charging entirely, thereby preventing harmful effects from improper connections.
3Reliability
If over-temperature protection function is added, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges the temperature detection function with the existing control unit and charging control logic. Rather than adding a completely separate protection system, the temperature detection circuit integrates with the control unit that already manages charging current, allowing the same control unit to handle both charging control and temperature-based protection decisions.
Solution Approach 2:
The control unit is designed to perform multiple functions: normal charging control, temperature monitoring, and over-temperature protection. This multi-functional approach avoids the need for separate dedicated protection hardware, reducing overall system complexity while maintaining comprehensive safety functionality.
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 solution effectively minimizes the risk of component damage and ensures safe operation by reducing the charging current when high temperatures are detected, while maintaining reliable communication and detection of charging information.
Implementation Method 1
The temperature detecting circuit is electrically connected with the second control unit, and is configured to detect a temperature of the power plug or a temperature of the control box
Data Source
AI summary
A charging device for charging an electric vehicle includes a power plug, a charging gun, a control box, a temperature detecting circuit and an over-temperature protection circuit. The charging gun is detachably connected with the electric vehicle and includes a connection confirmation terminal and a connection confirmation circuit. The connection confirmation circuit outputs a connection confirmation signal to the connection confirmation terminal. The temperature detecting circuit detects the temperature of the power plug or the control box and outputs a temperature signal to a second control unit of the control box when the temperature of the power plug or the control box exceeds a threshold temperature level. The over-temperature protection circuit is electrically connected between the second control unit and the connection confirmation terminal. The second control unit controls the over-temperature protection circuit to adjust the voltage level of the connection confirmation terminal according to the temperature signal.