Vehicle Power Cable Connector With Adjustable Charging Current Limit
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Solution Overview
Problem
Existing power cable connectors for electric vehicles lack flexible current limitation capabilities, leading to potential overloading and tripping of household fuses when multiple vehicles are charged simultaneously or when other electrical consumers are used in parallel, resulting in reduced charging comfort and risk of interruptions.
Innovation Solution
A secondary connector with an adjustable and limiting unit that allows users to set a maximum current value, which is linked to the connection process and only active when the secondary connector is used, preventing inadvertent retention of low current limitations across different charging situations, and featuring a detection unit to monitor current and prevent overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed current limitation is implemented in the power cable, then the power supply device is protected from overloading, but the charging flexibility is reduced and low current limitations may be inadvertently retained across different charging situations
Solution Approach 1:
The patent implements a dynamic current limitation system where the limiting unit can be adjusted or deactivated based on the charging situation. The secondary connector allows users to adapt the current limitation setting to match different power supply capabilities, transitioning from a static fixed limitation to a dynamic adjustable limitation that optimizes both safety and charging flexibility.
Solution Approach 2:
The patent enables parameter changes by allowing the current limitation value to be modified through the adjusting unit. This permits the system to adapt to different charging scenarios by changing the current parameter, whether increasing it for higher capacity power supplies or decreasing it for lower capacity sources, thereby resolving the contradiction between fixed protection and flexible adaptability.
2Adaptability or versatility
If the secondary connector with adjustable current limitation is used, then charging flexibility is improved, but the device complexity increases
Solution Approach 1:
The secondary connector is designed to perform multiple functions: it provides electrical connection, enables current limitation, and allows adjustment of the limitation parameter. By integrating these functions into a single universal component, the patent achieves charging flexibility without proportionally increasing complexity, as the same hardware structure supports both limitation and adjustment capabilities.
Solution Approach 2:
The patent combines the limiting unit and adjusting unit into the secondary connector assembly, merging multiple functional elements into a single integrated device. This consolidation approach achieves the desired flexibility while managing complexity by avoiding separate independent components for each function.
3Productivity
If no current limitation is implemented, then charging speed is maximized, but the power supply device may be overloaded and fuses may trip
Solution Approach 1:
The patent implements a feedback mechanism where the limiting unit monitors the charging current and adjusts it to remain within safe limits for the connected power supply. This feedback control allows the system to operate at maximum safe capacity, optimizing charging speed while preventing overload conditions that would cause fuse tripping, thus resolving the contradiction between speed and reliability.
Data Source
AI summary
A secondary connector of a power cable which is designed for electrical connection to a vehicle. The secondary connector includes a plug-in connector for detachable electrical connection to a power supply device, in particular a cable connection for detachable electrical connection to a coupling of the power cable, a limiting unit which is designed to limit an electric current flowing through the power cable to a maximum value, and an adjusting unit via which the maximum value can be adjusted.