Relay Housing Layout for Low-Loss EV Quick Charging
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Solution Overview
Problem
Existing charging devices for electric and hybrid vehicles experience significant power loss during quick charging due to long cable lengths, which increases resistance and heat loss, especially when high currents are required.
Innovation Solution
The charging device incorporates a housing that positions the charging connection portion adjacent to the charging connector and the battery connection portion adjacent to the battery, thereby reducing the length of the relay and battery cables, and includes a relay to switch direct current supply to the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the charging device uses long cables to connect the charging connector and battery, then the device can be arranged flexibly in the vehicle, but power loss increases due to increased resistance and heat loss
Solution Approach 1:
The charging device is divided into separate functional modules: a charging connector module, a battery connector module, and a relay module housed in separate housings. This segmentation allows each module to be positioned independently to minimize cable lengths while maintaining arrangement flexibility in the vehicle.
Solution Approach 2:
A relay is introduced as an intermediary component between the charging connector and the battery. The relay housing is positioned between the charging connector housing and battery connector housing, serving as an intermediate station that allows cable routing to be optimized for minimum length while maintaining system functionality.
2Productivity
If high current is supplied for quick charging, then charging speed increases, but heat loss and power loss increase due to cable resistance
Solution Approach 1:
The housing arrangement creates an asymmetric layout where the relay housing is positioned closer to the battery connector than to the charging connector. This asymmetric positioning optimizes the cable path lengths differently for each connection, minimizing the total resistance in the high-current path while allowing flexible vehicle integration.
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 configuration effectively reduces power loss during quick charging by minimizing cable length, improving charging efficiency, and reducing the influence of heat-related losses.
Implementation Method 1
a relay that switches the direct current to be supplied or not relative to the battery
Implementation Method 2
the relay cable having one end connected to the charging connector... a battery cable having one end connected to the battery... effectively reduces power loss during quick charging by minimizing cable length
Data Source
AI summary
A charging device includes: a relay cable having one end connected to a charging connector; a battery charged by a direct current supplied from the charging connector; a battery cable having one end connected to the battery; a charging connection portion connected to the other end of the relay cable; a battery connection portion connected to the other end of the battery cable; a relay that switches the direct current to be supplied or not relative to the battery; and a housing arranged between the battery and the charging connector so as to house the relay. The charging connection portion is arranged on the housing adjacent to the charging connector, and the battery connection portion is arranged on the housing adjacent to the battery.