EV Charging Plug Temperature Sensing for Fast Fault Response
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Solution Overview
Problem
Existing temperature monitoring devices for electric vehicle battery charging cables lack efficient temperature sensing and control mechanisms, particularly in recognizing plug configurations and managing temperature conditions to ensure safe and optimal charging.
Innovation Solution
The electric vehicle supply equipment device incorporates a removable grid cord with temperature sensing elements and a control module that communicates temperature conditions via an electrical power carrying conductor, enabling classification recognition and temperature monitoring, and includes an in-cable control protection device for safe power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If temperature sensing elements are placed close to current carrying blades for fast response, then response time is improved, but device complexity increases
Solution Approach 1:
The temperature sensing elements are integrated within the electrical plug housing, nested around the current carrying blades. This nesting arrangement allows the sensors to be positioned in close proximity to the blades for fast temperature detection while maintaining a compact, organized structure that does not significantly increase overall device complexity
Solution Approach 2:
The temperature monitoring function is merged with the electrical plug structure itself. The sensing elements, control module, and communication components are combined into a single integrated device housed within the plug, eliminating the need for separate monitoring equipment and reducing overall system complexity
2Measurement precision
If multiple temperature sensing elements are used to monitor each current carrying blade, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Temperature sensing is applied locally at each current carrying blade position rather than using a single general sensor. Each sensing element is strategically positioned to monitor the temperature of its corresponding blade, providing localized and precise temperature data where it is most needed for safety monitoring
Solution Approach 2:
The control module serves multiple functions: it receives signals from multiple temperature sensing elements, processes the temperature data, determines temperature conditions, and communicates with the IC-CPD. This multi-functionality consolidates what could be multiple separate components into a single unit, reducing overall device complexity while maintaining measurement precision
3Ease of operation
If control module communicates temperature conditions via power carrying conductor, then ease of operation is improved, but reliability worsens due to potential interference
Solution Approach 1:
The electrical power carrying conductor is made multi-functional by using it for both power delivery and temperature condition communication. This eliminates the need for separate communication wiring, simplifying the device operation and installation while maintaining reliable communication through the existing robust power conductor infrastructure
Solution Approach 2:
The control module continuously monitors temperature conditions and communicates this information back through the power carrying conductor to the IC-CPD. This feedback mechanism enables real-time monitoring and response to temperature changes, improving operational reliability through continuous status reporting using the existing conductor
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 solution effectively monitors and manages temperature conditions of the electrical plug, ensuring safe charging by preventing overcurrent and enabling features like ground fault detection, while improving response time through proximity of sensors to current carrying blades.
Implementation Method 1
a plurality of temperature sensing elements each arranged proximally to a current carrying blade of an electrical plug
Data Source
AI summary
An electric vehicle supply equipment device includes a removable grid cord having an electrical plug and a device housed within the electrical plug. The device has a plurality of temperature sensing elements, a control module, and an electrical circuit electrically coupling the plurality of temperature sensing elements and the control module, the electrical circuit having an electrical power carrying conductor. The device further includes an in-cable control protection device. The control module communicates an indication of a temperature condition of the electrical plug to the in-cable control protection device via the electrical power carrying conductor.