EV Charging Plug Thermal Monitoring via PCB Sensors
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Solution Overview
Problem
Existing electric vehicle charging infrastructure lacks effective means to detect imminent overheating at the plug connection, particularly during improper use of the charging cable, which can lead to infrastructure damage and safety issues.
Innovation Solution
A charging plug apparatus equipped with a printed circuit board carrying temperature sensors and a Hall sensor, connected via thermally conductive contact areas to the contact pins, which communicates with an in-cable control box to monitor and manage the temperature profile between the charging bushing and plug, enabling early detection of overheating and appropriate action such as current reduction or disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are added to detect overheating at the plug connection, then safety and reliability are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple temperature sensors (NTC elements) directly into the printed circuit board of the charging plug, merging the temperature detection function with the existing control electronics. This integration approach enables overheating detection without adding separate complex sensor systems, thus improving safety while minimizing the increase in device complexity.
Solution Approach 2:
The patent uses the existing signal lines and control electronics in the charging plug as intermediaries to transmit temperature data from the sensors to the charging control system. This allows the temperature detection function to be implemented using existing infrastructure, reducing the need for additional complex components and simplifying the overall system architecture.
2Measurement precision
If multiple sensors are integrated on the printed circuit board, then measurement precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple temperature sensors (NTC elements) directly onto the printed circuit board, combining multiple measurement functions into a single manufacturing platform. This approach enables precise temperature monitoring at multiple critical points while using standard PCB manufacturing processes, thereby improving measurement precision without significantly increasing manufacturing complexity.
Solution Approach 2:
The printed circuit board serves multiple functions: it provides structural support, electrical connections, and a mounting platform for multiple temperature sensors. This multi-functionality allows the same manufacturing process to produce a complex sensor array, improving measurement precision while keeping manufacturing relatively simple through standardized PCB techniques.
3Reliability
If real-time temperature monitoring is implemented, then reliability is improved, but energy consumption increases
Solution Approach 1:
The patent implements temperature monitoring that activates during the charging process, using the existing charging current as the power source. The system periodically checks temperature conditions and compares them against threshold values, enabling real-time safety monitoring while consuming minimal energy only when charging is active, thus improving reliability without excessive energy consumption.
Solution Approach 2:
The temperature monitoring system uses the existing charging power supply and control electronics to perform self-diagnosis and safety monitoring. The NTC sensors are powered through the existing signal lines during charging, and the control unit automatically processes temperature data and triggers safety responses, eliminating the need for separate power sources and reducing overall energy consumption.
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
Prevents overheating by ensuring compatibility checks before charging and allowing for real-time temperature monitoring, reducing the risk of infrastructure damage and ensuring safe operation.
Implementation Method 1
Temperature sensors and a Hall sensor carried by the printed circuit board can be provided for checking the plug connection
Implementation Method 2
Thermally conductive contact areas may be provided on the printed circuit board and may be connected directly to the contact pins for coupling the temperature sensors to the contact pins
Implementation Method 3
U.S. Pat. No. 8,573,994 and DE 20 2008 009 929 U1 disclose attempts to use a Hall sensor to check the correct fitting of the charging plug in the coupling or bushing
Data Source
AI summary
A charging plug (10) for an electric vehicle having has contact pins (L1, N, PE) for establishing a plug connection to a coupling, and temperature sensors (NTC1, NTC2, NTC3) that are coupled thermally to the contact pins (L1, N, PE) for detecting a temperature profile between the charging plug (10) and the coupling.