Research Papers

Electrical Contact Resistance Estimation With Application to Electric Vehicle Charging Cable

[+] Author and Article Information
Jocelyn Sabatier

IMS Laboratory,
Bordeaux University,
Talence 33405, France
e-mail: jocelyn.sabatier@u-bordeaux.fr

Mathieu Chevrié

IMS Laboratory,
Bordeaux University,
Talence 33405, France
e-mail: mathieu.chevrie@u-bordeaux.fr

Christophe Farges

IMS Laboratory,
Bordeaux University,
Talence 33405, France
e-mail: christophe.farges@u-bordeaux.fr

Franck Guillemard

Scientific and Future Technologies Department,
PSA Groupe,
Vélizy-Villacoublay 78943, France
e-mail: franck.guillemard@mpsa.com

Laetitia Pradere

Scientific and Future Technologies Department,
PSA Groupe,
Vĺizy-Villacoublay 78943, France
e-mail: laetitia.pradere@mpsa.com

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT, AND CONTROL. Manuscript received November 9, 2016; final manuscript received August 1, 2017; published online November 10, 2017. Assoc. Editor: Shankar Coimbatore Subramanian.

J. Dyn. Sys., Meas., Control 140(4), 041003 (Nov 10, 2017) (7 pages) Paper No: DS-16-1545; doi: 10.1115/1.4037531 History: Received November 09, 2016; Revised August 01, 2017

The paper proposes a method to estimate the contact resistance inside the outlet between a charging cable and an electric vehicle. First, an electrothermal model of some components close to the contact area inside the vehicle outlet (in the female part of the outlet) and of the harness inside the vehicle is proposed. The charging cable and the associated components are the male parts of the outlet and are not modeled as these components are not identical for each charging. They also depend on the mode and the charging infrastructure used. It is only supposed that the charging cable evacuates an unknown thermal heat rate. A linear approximation of the electrothermal model is then obtained and used to design a closed-loop estimator of the total heat rate at the contact area. Using this information, a least square method is used to estimate the contact resistance that can be deduced from the first values of the total heat rate after a step variation of the current in the charging cable.

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Fig. 1

Front view representation of a car outlet

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Fig. 2

Harness between the car outlet and the converter

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Fig. 3

Scheme of the considered thermal chain

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Fig. 4

Electrical scheme of the testing bench

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Fig. 5

Heat rates ϕJ, ϕr↔ca and ϕt generated by an electrical current in the charging cable (top) and zoom in the first instants (bottom)

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Fig. 6

Closed-loop diagram to estimate the unknown total heat rate at the contact area

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Fig. 7

Thermocouple location inside the cylindrical part of the tab

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Fig. 8

Bode diagrams of G(s) for various ambient temperatures (top plots) and magnification around low frequencies (bottom plots)

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Fig. 9

Open-loop Nichols locus (top) and enlargement around ωu (bottom)

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Fig. 10

True total heat rate, estimated total heat rate, and rebuilt heat rate by the least squares method



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