1. Temperature sensor monitoring
The temperature protection of the USA Standard AC EV Charger first relies on the accurate monitoring of the temperature sensor. Temperature sensors are installed near key heat-generating components inside the charger, such as power conversion modules and transformers. These temperature sensors usually use temperature-sensitive components such as thermistors. When the charger is working, the temperature sensor continuously monitors the temperature of the components and converts the temperature signal into an electrical signal. For example, the resistance of a thermistor changes as the temperature rises, thereby changing the voltage or current value in the circuit. These electrical signals are transmitted to the charger's control unit to provide a basis for subsequent temperature control decisions.
2. Decision-making mechanism of the control unit
After receiving the signal from the temperature sensor, the control unit of the USA Standard AC EV Charger will make a judgment based on the preset temperature threshold. If the detected temperature is lower than the upper limit of the normal operating temperature range, the charger will continue to work normally. However, when the temperature reaches or exceeds the preset threshold, the control unit will initiate the corresponding protection measures. The setting of this threshold is rigorously tested, taking into account the heat resistance of the internal components of the charger and the temperature range of safe operation. For example, for a power conversion chip, its safe operating temperature may be set at around 80-90 degrees Celsius. When the temperature feedback from the temperature sensor reaches this value, the control unit will determine that temperature protection is required.
3. Execution of protection measures
Once the control unit determines that temperature protection is required, a series of measures will be implemented. A common way is to reduce the charging power. By adjusting the working parameters of the power conversion module, reducing the input power or changing the output power, the heat generated inside the charger can be reduced. This allows the temperature to gradually drop without interrupting the charging process. If the temperature continues to rise and exceeds a higher level threshold (such as 95-100 degrees Celsius), the control unit may directly cut off the charging circuit and stop charging to prevent the internal components of the charger from being damaged due to overheating. At the same time, in some chargers, the user will be prompted that the charger has an overtemperature condition by flashing the indicator light or sending a specific fault code when communicating with the electric vehicle.
4. Collaboration between heat dissipation design and temperature protection
In addition to the above-mentioned active temperature protection measures, the heat dissipation design of the USA Standard AC EV Charger also works in conjunction with temperature protection. Good heat dissipation design, such as heat sinks and fans, can effectively dissipate the heat generated inside the charger. Under normal circumstances, the heat dissipation system can maintain the internal temperature of the charger within a reasonable range. When the heat dissipation system fails to work properly for some reason (such as fan failure, heat sink blockage, etc.), causing the temperature to rise, the temperature protection mechanism will come into play to prevent the charger from overheating and causing safety hazards.
