Mode 2 Charging Cable Galvanic Protection
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Solution Overview
Problem
Existing mode 2 charging cords for electric and hybrid vehicles face issues with high costs, safety risks, and interference with differential protection due to complex wiring arrangements, which can lead to electrical fires and increased charging times.
Innovation Solution
A charging cord design featuring a second control wire coupled with galvanic protection means that isolate the control circuit from the phase and neutral wires, preventing direct current flow and simplifying protection mechanisms, while using opto-couplers or transformers to warn the control means of the circuit state, and incorporating auxiliary protection components like resistive and capacitive components to ensure safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two different sub-parts of the electric cable are used for control wires, then the control function is achieved, but the cost increases and safety risks arise
Solution Approach 1:
The patent applies homogeneity by using two identical cable sub-parts instead of different types. Both sub-parts contain the same configuration of wires (phase, neutral, earth, and control wires), making them interchangeable and simplifying the overall cable structure while maintaining control functionality.
Solution Approach 2:
The identical cable sub-parts serve multiple functions: they provide both power transmission and control signals simultaneously. Each sub-part is designed to handle all necessary electrical connections, eliminating the need for specialized different cable types.
2Ease of operation
If control wires are directly connected to phase and neutral wires, then the control circuit functions, but safety risks increase due to potential contact and electrical fires
Solution Approach 1:
The patent introduces an optical coupler as an intermediary device between the control circuit and the power circuit. The optical coupler receives control signals and transmits them optically to the other side of the isolation barrier, preventing direct electrical contact between control wires and power wires while maintaining control functionality.
Solution Approach 2:
The patent replaces the direct electrical (mechanical) connection between control and power circuits with an optical transmission system. The optical coupler converts electrical signals to optical signals and back, eliminating the need for direct wire-to-wire contact and thereby preventing electrical fire risks.
3Productivity
If current flows in the electric circuit for charging, then charging function is achieved, but differential protection means are disturbed causing edge effects
Solution Approach 1:
The optical coupler acts as an intermediary that isolates the control circuit from the power circuit. This isolation prevents charging current from flowing into the control circuit and interfering with differential protection means, while still allowing control signals to be transmitted effectively for maintaining charging functionality.
4Object-affected harmful factors
If complex wiring arrangements are used for galvanic protection, then safety is improved, but cost and complexity increase
Solution Approach 1:
The optical coupler provides galvanic isolation in a single integrated component, replacing what would otherwise require complex multi-wire isolation arrangements. This approach maintains electrical safety by preventing current flow between circuits while simplifying the wiring structure.
Solution Approach 2:
The patent extracts the galvanic isolation function from the wiring arrangement itself and places it in a dedicated optical coupler component. This separation allows the wiring to remain simple while the isolation function is performed by the specialized optical device.
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 design reduces costs by using two identical cable sub-parts, enhances safety by preventing electrical fires, and minimizes interference with differential protection, allowing for efficient and safe charging without disturbing the control box's protection mechanisms.
Implementation Method 1
The galvanic protection means may comprise an optical coupler capable, in the event of a current flowing in the electric circuit, of generating another current intended to warn the control means of the placement of the electric circuit in its first state
Implementation Method 2
the galvanic protection means can comprise a transformer having primary and secondary windings. In this case, the secondary winding is capable of generating a current which is intended to warn the control means of the placement of the electric circuit in its first state in the event of circulation in the primary winding of a current which comes from the electric circuit
Implementation Method 3
Generally the second means of action of the power outlet are in the form of a magnet intended to act on the first means of action of a charging cord, which are in the form of at least one switch magnetic blade
Data Source
Figure 1~2
Figure 3~4
AI summary
A charging cable (CC) comprising i) a first plug (P1) capable of being connected to an electrical socket and comprising first operating means (L) specific to placing an electrical circuit in a first state in the event of cooperation with second operating means of the electrical socket, ii) a second plug (P2) capable of being connected to a socket in a vehicle, iii) an electrical cable (CA) comprising at least neutral wires (FN) and live wires (FP) interconnecting the first (P1) and second (P2) plugs, and iv) a control unit (BC) comprising control means (MC) coupled with the electrical circuit and arranged to send a signal to a first control wire (FC1), connected to the second plug (P2), when the electrical circuit is in its first state. The electrical circuit comprises a second control wire (FC2) coupled with the first operating means (L), a first connection connecting the first operating means (L) to either the neutral wire (FN) or the live wire (FP), a second connection connected to the remaining neutral wire (FN) or live wire (FP), and galvanic protection means (MP) connected to the second control wire (FC2) and to the second connection and arranged to provide galvanic protection of the control means (MC) in relation to the neutral wire (FN), the live wire (FP) and the second control wire (FC2), and for warning the control means (MC) when the electrical circuit is in its first state. (Figure 1)