Wireless EV Charging Inspection System
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Solution Overview
Problem
Conventional electric vehicle charging inspection methods are inefficient due to coupler compatibility issues, excessive operation time, and interference, requiring manual intervention and additional work processes, which prolong the inspection time beyond the desired 60 seconds.
Innovation Solution
A wireless charging inspection system that aligns transmission and reception pads according to vehicle type, uses a wireless diagnostic communication to inspect the high voltage battery's management, cooling, and charging systems, and automatically performs inspections without worker intervention, reducing operation time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wired charging inspection using charging coupler is performed, then charging performance can be inspected, but inspection time is excessively long (131 seconds) and exceeds the desired 60 seconds
Solution Approach 1:
The patent replaces the mechanical wired charging inspection system with a wireless charging inspection system. The wireless charging device transmits power wirelessly to the vehicle battery through electromagnetic fields, eliminating the need for physical coupler connection and disconnection operations. This substitution reduces inspection time from 131 seconds to under 60 seconds while maintaining charging performance measurement capability.
Solution Approach 2:
The patent extracts and removes the time-consuming manual operations (coupler connection, disconnection, and reconnection steps) from the inspection process. By using wireless charging, the system eliminates the need for workers to physically connect and disconnect charging cables, removing these harmful time elements from the inspection workflow.
2Adaptability or versatility
If multiple charging couplers (DC combo, CHAdeMO, AC 3-phase, Supercharger, 9 pin) are used for inspection, then various charging types can be tested, but coupler compatibility problems and interference occur
Solution Approach 1:
The wireless charging device serves as a universal inspection tool that can test all types of vehicle batteries regardless of their original charging coupler type. The wireless power transmission system is compatible with different battery chemistries and vehicle models (BEV, PHEV, HEV) without requiring specific coupler adapters, providing multi-functional inspection capability in a single system.
Solution Approach 2:
The wireless charging device acts as an intermediary that bypasses the need for vehicle-specific charging couplers. Instead of directly connecting to various proprietary couplers (which cause compatibility and interference issues), the wireless system transmits power through electromagnetic fields as an intermediate medium, eliminating coupler-related problems while maintaining the ability to charge different battery types.
3Ease of operation
If manual worker intervention is used for charging inspection, then connection and disconnection can be performed, but extra work processes and operation hours are excessively generated
Solution Approach 1:
The wireless charging inspection system is designed to operate autonomously without requiring manual worker intervention. The system automatically positions the vehicle, initiates wireless power transmission, monitors charging parameters, and completes the inspection process. This self-service capability eliminates the need for workers to perform connection/disconnection tasks, significantly improving inspection throughput while maintaining operational simplicity.
4Measurement precision
If wired charging inspection is performed with charging cable and coupler, then charging function can be tested, but interference on operation and influence on charging/communication may occur
Solution Approach 1:
The patent replaces the mechanical wired connection system with a wireless electromagnetic field-based power transmission system. This substitution eliminates physical contact between charging equipment and vehicle, removing sources of electrical interference, communication disruption, and operational interference that are inherent in wired coupler connections while maintaining the ability to accurately test charging function.
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 system significantly reduces inspection time by automating the process, adapts to various vehicle types without extra facilities, and improves the quality of electric vehicles by systematically inspecting key components, thereby preempting production challenges.
Implementation Method 1
a wireless charger configured to transmit electric power for a wireless charging of a high voltage battery through a transmission pad
Data Source
AI summary
A system for inspecting wireless charging of an electric vehicle includes: a wireless charger configured to transmit electric power through a transmission pad disposed on an inspection reference line of a rail; a centering unit configured to align a position of a reception pad on a vertical position of the transmission pad through a driving roller on which the electric vehicle is positioned; and an inspector configured to connect a wireless diagnosing communication, wirelessly charge a high voltage battery, and integrally inspect operation status of at least one of a battery management system (BMS), a battery cooling system, a battery charging system, or a high voltage distribution system during the wireless charging of the high voltage battery by receiving a test information from an electric power control unit (EPCU) of the electric vehicle connected through the wireless diagnosing communication.