Electrical Plug Temperature Sensing via Power Conductors
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Solution Overview
Problem
Existing temperature monitoring devices for battery charging cables lack efficient and precise temperature sensing capabilities, particularly in varying electrical plug configurations, which can lead to inadequate safety features and charging control.
Innovation Solution
A temperature monitoring device with thermistors mounted on a printed circuit board within the electrical plug, allowing for proximity to current carrying blades, and a control module that communicates temperature data via the electrical power conductor using a communication protocol to enable real-time monitoring and safety features like ground fault detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature sensors are integrated into the charging cable, then temperature monitoring capability is improved, but device complexity increases
Solution Approach 1:
The charging cable is designed to perform multiple functions: it serves as both the power transmission medium and the temperature monitoring system. The existing electrical conductors in the cable are utilized for dual purposes - carrying charging current and transmitting temperature sensor signals, thereby integrating temperature monitoring into the cable structure without adding separate monitoring systems.
Solution Approach 2:
The temperature monitoring function is merged with the charging cable structure itself. Temperature sensors are physically integrated within the cable insulation layers, and the signal transmission pathway is combined with the existing electrical conductors, creating a unified system that eliminates the need for separate monitoring devices.
2Measurement precision
If multiple temperature sensors are used for precise monitoring, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Temperature sensors are strategically positioned at specific locations within the charging cable where temperature monitoring is most critical - namely, in the insulation layers surrounding the electrical conductors. This localized placement ensures precise measurement at the points of highest thermal risk while minimizing the total number of sensors required.
Solution Approach 2:
Rather than implementing comprehensive temperature monitoring throughout the entire cable length, the system uses a selective approach by placing sensors only at key monitoring points in the insulation layers. This partial monitoring strategy achieves sufficient measurement precision for safety purposes while keeping the system simple.
3Measurement precision
If temperature sensors are placed close to current carrying blades, then temperature detection accuracy is improved, but manufacturing difficulty increases
Solution Approach 1:
The temperature sensors are nested within the multi-layer insulation structure of the charging cable, specifically positioned in the insulation layers that surround the current-carrying conductors. This nested placement allows the sensors to be in close proximity to the heat-generating elements while maintaining the integrity of the cable's manufacturing process through a layered construction approach.
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 precise temperature monitoring and real-time control of charging processes across different plug configurations, ensuring safe and efficient battery charging by accurately detecting temperature conditions and preventing overcharging or faults.
Implementation Method 1
A first temperature sensor including a first thermistor arranged non-integrally to the control module and a second temperature sensor including a second thermistor arranged non-integrally to the control module
Implementation Method 2
The control module is configured to communicate, via the electrical power carrying conductor, an indication of a classification of the electrical plug
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A device (20) comprises a plurality of temperature sensing elements (24) and a control module (38). The plurality of temperature sensing elements (24) are arranged proximally to a current carrying blade (18) of an electrical plug (14). The control module (38) receives a plurality of temperature signals (42) that each indicate a current carrying blade temperature associated with the electrical plug (14) from the plurality of temperature sensing elements. The control module (38) also determines a temperature condition of the electrical plug (14) based on the plurality of temperature signals (42). The control module (38) also communicates an indication of the temperature condition (22) of the electrical plug (14) by disrupting electrical power (16) carried by an electrical power carrying conductor (44) that supplies electrical power (16) via the electrical plug (14).