Thermal Wall Plug Sensing and Adaptive Current Control
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Solution Overview
Problem
Existing charging systems for plug-in electric and hybrid electric vehicles lack effective temperature monitoring and control strategies at the wall plug connection, leading to potential inefficiencies and safety concerns due to heat generation during current flow.
Innovation Solution
A plug assembly with integrated temperature sensors, such as NTC or PTC devices, is used to monitor temperature at the wall outlet connection, allowing the vehicle charging system to adjust current flow based on temperature readings, ensuring safe and efficient charging operations by reducing current as temperature increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If current flow is increased to support charging operations, then charging speed and efficiency are improved, but heat generation at the wall outlet connection increases
Solution Approach 1:
The patent implements a feedback control system where a temperature sensor continuously monitors the temperature at the wall outlet connection and provides real-time temperature data to a controller. The controller adjusts the current flow through the charging system based on the detected temperature, reducing current when temperature exceeds thresholds and restoring current when temperature is within safe ranges. This closed-loop feedback mechanism dynamically balances charging speed with thermal safety.
Solution Approach 2:
The system dynamically adjusts the current flow characteristics based on real-time temperature conditions. Rather than using a fixed current rate, the controller modifies the current magnitude and potentially the charging profile (e.g., switching between different charging stages) in response to temperature changes. This dynamic adaptation allows the system to optimize charging speed while preventing overheating at the wall outlet connection.
2Reliability
If temperature monitoring and control systems are added to the charging system, then safety and thermal management are improved, but device complexity increases
Solution Approach 1:
The patent integrates temperature monitoring and control functions into the existing charging system infrastructure. The controller performs multiple functions including current regulation, temperature monitoring, and safety control within a single integrated unit. The temperature sensor is incorporated into the plug assembly housing, sharing the same physical space and control electronics. This multi-functional integration adds safety capabilities without proportionally increasing system complexity.
Solution Approach 2:
The system uses a simple temperature sensor as an intermediary element that bridges the thermal condition at the wall outlet connection and the control system. Rather than implementing complex thermal modeling or multiple sensing points, a single temperature sensor provides sufficient information for the controller to make informed current adjustment decisions. This intermediary approach adds minimal complexity while achieving effective thermal management.
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
The solution enables real-time temperature monitoring and adaptive current control, preventing overheating and optimizing charging efficiency by reducing current flow proportionally with temperature, thus ensuring safe and efficient charging operations.
Implementation Method 1
The sensed temperature can be used to facilitate controlling charging system operations... a temperature sensor operable to detect a temperature at the wall outlet... a resistance of the temperature sensor approximates the temperature at the wall outlet
Implementation Method 2
the temperature sensor is one of a negative temperature coefficient (NTC) device, a positive temperature coefficient (PTC) device, and a thermistor
Implementation Method 3
the temperature sensor is one of a negative temperature coefficient (NTC) device, a positive temperature coefficient (PTC) device, and a thermistor
Implementation Method 4
heat generation during current flow
Data Source
AI summary
A system and method operable to facilitate thermal wall plug sensing and control may include an ability to control current drawn by a charging system or other load according to a temperature determined at an interface between the charging system and an energy source used to provided energy to the charging system. A temperature sensed with a temperature sensor included in a plug assembly or other housing or cord used to connect the charging system to the energy source may be used to implement the temperature regulated current control.