Sensor Line Assembly for Hot Spot Detection in Charging Cables
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor technologies for monitoring temperature along charging cables for electromotively driven motor vehicles lack efficient and precise methods for detecting temperature changes and locating 'hot spots' along the cable length, which can lead to overheating and damage.
Innovation Solution
A sensor line with a line core and spaced resistance elements, where the conductor has multiple turns in specific measuring portions to increase resistivity, allowing for localized detection of ambient variables like temperature, and is integrated into the charging cable for continuous monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple resistance elements are distributed along the sensor line, then spatial resolution for detecting hot spots is improved, but device complexity increases due to multiple conductors and turns required for each resistance element
Solution Approach 1:
The sensor line is segmented into multiple measuring portions along its length, with each portion containing a resistance element formed by conductor turns. This segmentation enables spatial resolution for detecting hot spots at different locations along the charging cable, while each segment can be independently evaluated to identify temperature anomalies.
Solution Approach 2:
Different portions of the conductor have different functions: sections with multiple turns create high resistivity for temperature sensing, while straight sections provide low-resistance connections. This local differentiation of conductor quality allows the sensor line to achieve both measurement precision and manageable complexity by optimizing each section's structure for its specific purpose.
2Measurement precision
If the conductor has multiple turns in measuring portions, then temperature detection sensitivity is improved, but manufacturing complexity increases due to the winding process
Solution Approach 1:
The conductor follows a periodic pattern of winding and straight sections along the sensor line. This periodic structure creates repeating measuring portions with high resistivity separated by low-resistance connection sections, enabling systematic temperature detection while simplifying manufacturing through a regular, repeatable winding pattern that can be automated.
Solution Approach 2:
The conductor's physical configuration changes periodically between wound sections (high resistivity) and straight sections (low resistivity). By controlling the winding parameters such as turn density and section length, the sensor achieves optimized temperature detection sensitivity while maintaining manufacturability through standardized geometric parameters.
3Measurement precision
If resistance elements are spaced apart along the sensor line, then coverage for detecting ambient variables is improved, but the sensor line becomes more vulnerable to mechanical damage
Solution Approach 1:
The sensor line structure serves multiple functions simultaneously: the spaced resistance elements provide temperature detection coverage along the cable length, while the continuous line core and conductor structure provide mechanical strength and protection against damage. This multi-functionality allows the sensor line to achieve both coverage and reliability without requiring separate protective systems.
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 accurate and spatially resolved temperature detection along the cable, identifying 'hot spots' and preventing overheating by correlating resistance value changes with temperature variations, ensuring the cable's safety and longevity.
Implementation Method 1
a respective resistance value varies in dependence on a value of the ambient variable
Data Source
AI summary
A sensor line, which is configured to detect an ambient variable and which extends from a first end to a second end in a longitudinal direction, has a line core and a number of mutually spaced resistance elements with a resistance value. The resistance value varies depending on a value of the ambient variables. A measuring assembly having the sensor line is also provided.