HV Contact Temperature Sensing With One Thermal Bridge Sensor
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Solution Overview
Problem
Existing high-voltage contact systems for monitoring temperature in battery-powered vehicles require additional installation space and complexity, leading to increased manufacturing costs, when using two temperature sensors for each high-voltage contact.
Innovation Solution
A high-voltage contact system utilizing a single temperature sensor thermally coupled to both direct-current contacts via a thermally-conductive and insulating elastomer, which forms a thermal bridge between the contacts and the sensor, allowing for efficient temperature measurement without the need for additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If two temperature sensors are used to monitor each high-voltage contact separately, then measurement precision is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines two separate temperature sensors into a single temperature sensor that monitors both high-voltage contacts. The sensor is positioned in the insulating element between the two contacts, allowing it to detect temperatures of both contacts simultaneously through thermal conduction, thereby reducing system complexity while maintaining monitoring capability
Solution Approach 2:
The single temperature sensor serves multiple functions by monitoring both the positive and negative high-voltage contacts. The insulating element acts as a thermal bridge, enabling one sensor to perform the work of two separate sensors, thus achieving multi-functionality and reducing overall system complexity
2Measurement precision
If two temperature sensors are used for each high-voltage contact, then measurement precision is improved, but installation space requirements increase
Solution Approach 1:
The patent merges two separate temperature sensing functions into a single sensor unit. By positioning this single sensor in the insulating element between the two contacts, both temperature measurements are obtained from one location, significantly reducing the installation space required compared to two separate sensors
3Measurement precision
If two temperature sensors are used for each high-voltage contact, then measurement precision is improved, but manufacturing costs increase
Solution Approach 1:
The patent combines two temperature sensor purchases and installations into one, directly reducing component costs. The single sensor integrated into the insulating element also simplifies assembly processes and reduces manufacturing complexity, leading to lower overall production costs while still providing dual contact temperature monitoring
Solution Approach 2:
The single temperature sensor performs the function of two sensors, reducing component procurement costs. The multi-functional design also simplifies manufacturing and assembly operations, further reducing production costs while maintaining the capability to monitor both high-voltage contacts
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 enables cost-effective and space-efficient temperature monitoring of high-voltage contacts, reducing system complexity and manufacturing costs while effectively detecting thermal overloading and mechanical damage due to aging.
Implementation Method 1
a thermally-conductive, electrically-insulating element embedded in the temperature sensor that makes contact with the two high-voltage contacts, the thermally-conductive, electrically-insulating element thereby forming a thermal bridge between the two HV-contacts and the temperature sensor
Implementation Method 2
a thermally-conductive, electrically-insulating element embedded in the temperature sensor that makes contact with the two high-voltage contacts
Data Source
AI summary
A high-voltage contact system with two high-voltage contacts which form a high-voltage connection in a battery-powered vehicle. A temperature sensor is arranged between the two high-voltage contacts and is designed to record a temperature based on the temperatures of both of the two high-voltage contacts. A thermally-conductive insulating element is embedded in the temperature sensor and contacts the two high-voltage contacts. The thermally-conductive insulating element forms a thermal bridge between the two HV-contacts and the temperature sensor so that the temperature sensor can record the temperature based on the temperatures of the two high-voltage contacts.