EV Charging Socket Leak Test via Cable Conductor
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Solution Overview
Problem
Existing methods for testing the tightness of charging sockets and line networks in vehicles often introduce additional sources of error or fail to reliably check the entire system without modifying it, particularly in high-voltage applications.
Innovation Solution
A leak test system comprising a test adapter, fluid supply, and measuring device that contacts a sealed connector in the line network, introducing a fluid under pressure to detect any leaks through the charging socket and cable, using a flow sensor to assess tightness by measuring flow rates and potentially employing gas sensors or optical techniques for enhanced detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional access point is provided on the housing for pressure testing, then the charging socket can be tested for tightness, but the additional access point becomes an additional source of leakage
Solution Approach 1:
The cable serves as an intermediary medium for pressure testing. Instead of providing direct access to the moisture-proof compartment through the housing, the testing system introduces pressure through the cable's conductor, which acts as a closed conduit. This allows tightness verification without creating additional access points that could compromise the housing seal.
Solution Approach 2:
The invention uses pneumatic pressure testing by introducing a gas (typically compressed air) through the cable conductor to verify the tightness of the charging socket and housing. The pressure differential created during testing allows detection of leaks without requiring physical access to the sealed compartment.
2Reliability
If the entire wiring network is tested for leaks, then comprehensive tightness verification is achieved, but the testing system becomes more complex
Solution Approach 1:
The cable conductor serves multiple functions: it acts as both the electrical connection medium and the pressure transmission conduit for tightness testing. This multi-functionality eliminates the need for separate testing infrastructure, reducing overall system complexity while enabling comprehensive verification of the entire wiring network from the connector through the cable to the charging socket.
Solution Approach 2:
The cable network itself serves as the testing pathway. The existing electrical conductors and insulation are utilized for pressure testing without requiring additional dedicated test ports or access points. The system tests itself by using its own structural elements (cable and connector) as the testing medium.
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
Enables non-invasive, efficient testing of the entire high-voltage line network for leaks, including cable insulation, without introducing additional error sources, by measuring flow rates and detecting gas leaks, thus ensuring the integrity of the charging socket and line network.
Implementation Method 1
a fluid supply connected to the test adapter in such a way that it can provide fluid to the test adapter
Implementation Method 2
using a flow sensor to assess tightness by measuring flow rates
Implementation Method 3
potentially employing gas sensors or optical techniques for enhanced detection
Data Source
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AI summary
A leak test device for a charging socket for supplying electrical energy to a vehicle's energy storage system is presented. The device comprises a test adapter for contacting a sealed connector of a wiring network, including the sealed connector itself; a charging socket for mounting on a vehicle with at least partial electric drive; a cable connecting the connector and the charging socket; a fluid supply connected to the test adapter and configured to provide fluid to the test adapter; and a measuring device for detecting the leak tightness of the charging socket and/or the wiring network based on the supplied fluid. Furthermore, a method for testing a charging socket for supplying electrical energy to a vehicle's energy storage system is described.