Leak detection in a cable assembly

Patent metadata

Field	Value
Publication number	US-11548398-B2
Application number	US-202017098041-A
Country	US
Kind code	B2
Filing date	Nov 13, 2020
Priority date	Nov 15, 2019
Publication date	Jan 10, 2023
Grant date	Jan 10, 2023

Abstract

A cable assembly includes a cable having a first end and a second end. The cable has an electric conductor and a cooling conduit, each of which extends from the first end to the second end. The cooling conduit is adapted to convey a fluid that cools the electric conductor. The cable assembly includes a leak detection module to detect a leak of the fluid from the cooling conduit. The leak detection module includes a power source to generate an input voltage signal which is applied at a first node contact with the fluid. The leak detection module includes a controller to monitor an output voltage signal at the first node and to detect a leak of the fluid from the cooling conduit based on the output voltage signal.

First claim

What is claimed is:

1. A cable assembly comprising:
a cable having a first end and a second end, the cable comprising an electric conductor and a cooling conduit, each of which extends from the first end to the second end, wherein the cooling conduit is adapted to convey a fluid that cools the electric conductor; and
a leak detection module coupled to the cable, the leak detection module comprising:
a power source to generate an input voltage signal wherein the input voltage signal is applied to the fluid at a first node in contact with the fluid; and
a controller configured to monitor an output voltage signal and to detect a leak of the fluid from the cooling conduit based on the output voltage signal.

2. The cable assembly of claim 1 , wherein the fluid is electrically conductive.

3. The cable assembly of claim 1 , wherein the cooling conduit is configured to convey the fluid from the first end to the second end, and thereafter from the second end to the first end.

4. The cable assembly of claim 1 , wherein the input voltage signal is an alternating current (AC) voltage signal.

5. The cable assembly of claim 1 , wherein the input voltage signal is further applied at a second node in contact with the fluid.

6. The cable assembly of claim 1 , wherein the controller detects the leak of the fluid when a peak-to-peak voltage of the output voltage signal drops more than a predetermined threshold voltage drop value.

7. The cable assembly of claim 1 , wherein the controller detects the leak of the fluid when a maximum voltage of the output voltage signal drops more than a predetermined threshold maximum voltage value.

8. The cable assembly of claim 1 , wherein the controller further provides, upon detecting the leak of the fluid, at least one of: a visual indication, an audio indication, or a tactile indication.

9. The cable assembly of claim 1 further comprising a connector attached to the second end of the cable, wherein the cooling conduit forms a fluid channel around an interior of a handle of the connector.

10. The cable assembly of claim 1 , wherein the cable assembly is used for charging an electric vehicle from a power supply.

11. The cable assembly of claim 10 , wherein the controller, upon detecting the leak of the fluid, automatically stops charging of the electric vehicle.

12. A cable assembly comprising:
a cable having a first end and a second end, the cable comprising an electric conductor and a cooling conduit, each of which extends from the first end to the second end, wherein the cooling conduit is adapted to convey a fluid that cools the electric conductor; and
a connector attached to the second end of the cable, wherein the cooling conduit forms a fluid channel around an interior of a handle of the connector and is adapted to cool the connector; and
a leak detection module coupled to the cable and the connector, the leak detection module comprising:
a power source to generate an input voltage signal wherein the input voltage signal is applied to the fluid at a first node in contact with the fluid; and
a controller configured to monitor an output voltage signal and to detect a leak of the fluid from the cooling conduit based on the output voltage signal.

13. The cable assembly of claim 12 , wherein the cable assembly is used for charging an electric vehicle from a power supply.

14. The cable assembly of claim 13 , wherein the controller, upon detecting the leak of the fluid, automatically stops charging of the electric vehicle.

15. The cable assembly of claim 12 , further comprising switches connected to a second node, wherein the second node is in contact with the fluid and wherein the switches are configurable to simulate the leak of the fluid.

16. The cable assembly of claim 12 , wherein the fluid is electrically conductive.

17. The cable assembly of claim 12 , wherein the cooling conduit is configured to convey the fluid from the first end to the second end, and thereafter from the second end to the first end.

18. The cable assembly of claim 12 , wherein the controller further provides, upon detecting the leak of the fluid, at least one of: a visual indication, an audio indication, or a tactile indication.

19. The cable assembly of claim 12 , wherein the controller detects the leak of the fluid when a peak-to-peak voltage of the output voltage signal drops more than a predetermined threshold voltage drop value.

20. The cable assembly of claim 12 , wherein the controller detects the leak of the fluid when a maximum voltage of the output voltage signal drops more than a predetermined threshold maximum voltage value.

21. A cable assembly comprising:
a cable having a first end and a second end, the cable comprising an electric conductor and a cooling conduit, each of which extends from the first end to the second end, wherein the cooling conduit is adapted to convey a fluid that cools the electric conductor; and
a leak detection module coupled to the cable, the leak detection module comprising:
a power source to generate an input voltage signal wherein the input voltage signal is applied to the fluid at a first node in contact with the fluid; and
a controller configured to monitor an output voltage signal and to characterize a leak of the fluid from the cooling conduit based on the output voltage signal based on a comparison of the monitored output voltage signal with two representative output voltage values, a first representative output voltage value associated with a fluid leak and a second representative output voltage value not associated with a fluid leak.

22. The cable assembly of claim 21 , wherein the fluid is electrically conductive.

23. The cable assembly of claim 21 , wherein the cable assembly is used for charging an electric vehicle from a power supply.

Assignees

• Tesla Inc

Inventors

• Fortin Pascal-Andre
• Sukup Martin
• Murphy Tim
• Chou Chuen
• Tedjarati Aria

Classifications

• H01B7/32

  with arrangements for indicating defects, e.g. breaks or leaks · CPC title

• H01B9/02

  with screens or conductive layers, e.g. for avoiding large potential gradients · CPC title

• B60L53/18 Primary

  Cables specially adapted for charging electric vehicles · CPC title

• Y02T90/14

  Plug-in electric vehicles · CPC title

• H01B7/423

  using a cooling fluid · CPC title