System and method for remotely testing the continuity of an electrical wiring

Abstract

Various embodiments disclosed by the present invention include an exemplary system for remotely testing the continuity of electrical wiring, an electric vehicle charging system, and a charge coupler for an electric vehicle charging system. In an exemplary embodiment, the system for remotely testing the continuity of electrical wiring includes a signal generator configured to generate a signal having a predetermined frequency. A controlled impedance network is configured to attenuate the signal. The controlled impedance network can be electrically connected towards a first end of the electrical wiring, which is terminated at a terminal at the first end and can be electrically connected to the signal generator at a second end to carry the signal. A signal detector is configured to detect the signal.

Description

[0001] Introduction

[0002] The present disclosure relates to testing the continuity of electrical wiring. The statements in this section merely provide background information relevant to the present disclosure and may not constitute prior art.

[0003] In settings where the wire is accessible to the user, the user can easily test the continuity of the wire by currently known devices and methods (such as by using any suitable continuity tester, multimeter, etc.). However, in other remote settings where the wire is not accessible to the user, the user cannot test the continuity of the wire by using currently known devices and methods (such as a continuity tester or multimeter). The difficulty of remotely testing the continuity of electrical wiring is exacerbated when the electrical wiring is terminated at a connector (without the need to be connected to its associated mating connector and attached circuitry).

[0004] An example of a remote setting is a direct current (DC) fast charging station for charging an electric vehicle. In level 3 charging (DC fast charging), alternating current (AC) power is supplied from the power grid to an electric vehicle supply equipment (EVSE). The EVSE also handles communication, but the AC voltage is converted to DC voltage via an AC-DC converter provided in the EVSE and which may have a rating greater than 200 KW. In the case of level 3 DC fast charging, the AC-DC converter on the electric vehicle is bypassed, and up to approximately 195 miles of range can be added per hour of charging. Thus, level 3 DC fast charging can be considered desirable for public charging infrastructure (such as for private vehicle fleets as well as charging stations that are also available to the public - hereinafter referred to as public charging stations).

[0005] The EVSE typically includes a power cabinet that receives AC power from the power grid and converts the grid AC power to DC power. The power cabinet supplies DC power to at least one distributor. Each distributor includes a charge coupler that is electrically connected to the distributor and to the electric vehicle to distribute DC power to the electric vehicle. An electrical connection piece called a control pilot provides a control pilot signal from the EVSE to the electric vehicle through the charge coupler to provide a communication integrity check between the EVSE and the electric vehicle.

[0006] Sometimes an electric vehicle may have charging problems and it may be difficult to remotely identify the cause (e.g., software issues versus hardware connections). Field service data shows that broken cables (connecting the charge coupler to its dispenser) account for a majority of the field service visits and replacement costs for public charging infrastructure. However, currently known systems and methods require the electric vehicle to be connected to an EVSE (at least SAE JI772 state Bl) to perform a communication integrity check between the EVSE and the electric vehicle. When the electric vehicle is not connected to the EVSE (SAE JI772 state A), currently known systems and methods cannot perform a communication integrity check between the EVSE and the electric vehicle. Summary of the Invention

[0007] Exemplary systems, electric vehicle charging systems, and charge couplers for an electric vehicle charging system for remotely testing the continuity of electrical wiring are disclosed in various embodiments of the present invention.

[0008] In an exemplary embodiment, a system for remotely testing the continuity of electrical wiring includes a signal generator configured to generate a signal having a predetermined frequency. A controlled impedance network is configured to attenuate the signal. The controlled impedance network can be electrically connected to a first end of the electrical wiring, which is terminated at a terminal at the first end and can be electrically connected to the signal generator at a second end to carry the signal. A signal detector is configured to detect the signal.

[0009] In another exemplary embodiment, an electric vehicle charging system includes a dispenser configured to receive and distribute direct current (DC) power. The dispenser includes at least one signal generator configured to generate a control pilot signal having a first frequency for low-level signaling, a power line communication signal having a second frequency range for high-level communication, and a continuity check signal having a third frequency different from the first frequency and the second frequency range. A signal detector is configured to detect the continuity check signal. A cable assembly includes a control pilot line and a ground wire, the control pilot line being electrically coupled to receive the control pilot signal, the power line communication signal, and the continuity check signal, the ground wire being able to be electrically connected to an equipment ground. A charge coupler is coupled to an end of the cable assembly. The charge coupler includes a housing. A controlled impedance network is disposed in the housing and is electrically connected between the control pilot line and the ground wire. The controlled impedance network is configured to attenuate the continuity check signal.

[0010] In another illustrative embodiment, a charge coupler for an electric vehicle charging system includes a housing. A DC contact is disposed in the housing and configured to be electrically coupled to distribute DC power to the electric vehicle. A control pilot line is disposed in the housing. The control pilot line is configured to receive a control pilot signal having a first frequency for low-level signaling, a power line communication signal having a second frequency range for high-level communication, and a continuity check signal having a third frequency different from the first frequency and the second frequency range. A ground wire is disposed in the charge coupler housing. The ground wire is configured to be electrically connectable to an equipment ground. A controlled impedance network is electrically connected between the control pilot line and the ground wire. The controlled impedance network is configured to attenuate the continuity check signal.

[0011] The foregoing summary is illustrative only and is not intended to be limiting in any way. In addition to the above illustrative aspects, embodiments, and features, additional aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Illustrative embodiments are shown in the reference figures of the drawings. The embodiments and the drawings disclosed herein are to be considered illustrative rather than restrictive.

[0013] Figure 1 A block diagram of an illustrative system for remotely testing the continuity of an electrical wiring.

[0014] Figure 2 A block diagram in the form of a partial schematic of an illustrative DC power distributor and an illustrative electric vehicle.

[0015] Figure 3A A block diagram of an illustrative electric vehicle charging system.

[0016] Figure 3B For Figure 3A A block diagram of an illustrative DC power distributor of the charging system of

[0017] Figure 3C For Figure 3B A block diagram of the details of the distributor of

[0018] Figure 3D A plot of voltage versus time of an illustrative control pilot signal for low-level signaling.

[0019] Figure 3E A spectral template of an illustrative control pilot signal for high-level communication.

[0020] Figure 4A A schematic diagram of an illustrative low-pass filter.

[0021] Figure 4B AndFigure 4C The Figure 4A illustration of the response of a low - pass filter.

[0022] Figure 5A is a schematic diagram of an exemplary notch filter.

[0023] Figures 5B to 5E The Figure 5A illustration of the response of a notch filter.

[0024] The same reference signs in the various figures generally indicate the same elements. Detailed Description

[0025] In the following detailed description, reference is made to the accompanying drawings, which form a part of the detailed description. In the drawings, like signs generally identify like components unless the context otherwise indicates. The exemplary embodiments described in the detailed description, the drawings, and the claims are not intended to be limiting. Other embodiments may be utilized and other changes may be made without departing from the spirit or scope of the subject matter presented herein.

[0026] The various embodiments disclosed herein include an exemplary system for remotely testing the continuity of electrical wiring, an electric vehicle charging system, and a charge coupler for an electric vehicle charging system.

[0027] Now referring Figure 1 And presented by way of overview, in various embodiments, an exemplary system 10 for remotely testing the continuity of electrical wiring 12 includes a signal generator 14 configured to generate a signal 16 having a predetermined frequency. A controlled impedance network 18 is configured to attenuate the signal 16. The controlled impedance network 18 can be electrically connected toward an end 20 of the electrical wiring 12, which is terminated at a terminal 22 at the end 20 and can be electrically connected to the signal generator 14 at an end 24 to carry the signal 16. A signal detector 26 is configured to detect the signal 16.

[0028] As will be described hereinafter, the various embodiments can help to provide testing of the continuity of electrical wiring 12. Still referring Figure 1 And still by way of overview, it should also be understood that in various embodiments, if the electrical wiring 12 is continuous and the signal 16 is applied to the electrical wiring 12, the controlled impedance network 18 will attenuate the signal 16 and the signal detector 26 will measure the attenuated signal 16. It should also be understood that in various embodiments, if the electrical wiring 12 is not continuous and the signal 16 is applied to the electrical wiring 12, the signal detector 26 measures the full - strength signal 16 with little, minimal, or no attenuation.

[0029] Now that the overview has been presented, exemplary details will be explained by way of example, which are given by way of illustration only and not limitation.

[0030] Still referring to Figure 1 , it should be understood that, depending on the needs of a particular application, the electrical wiring 12 can be any type of electrical wiring. No type of electrical wiring is intended to be restricted, and no restriction should be inferred. For clarity and conciseness, non-limiting examples will be given below by way of illustration only and not limitation, where the electrical wiring 12 is a control pilot wire suitable for an electric vehicle charging system. Similarly, it should be emphasized that the electrical wiring 12 is not limited to the non-limiting exemplary examples described below.

[0031] In various embodiments, the electrical wiring 12 is terminated at the terminal 22 at the end 20. Depending on the needs of a particular application, the terminal 22 can be any suitable terminal, such as a connector, plug, socket, the end of a wire (insulated or stripped), etc. In various embodiments, depending on the needs of a particular application, the end 24 of the electrical wiring 12 can be electrically connected to the signal generator 14 in any suitable manner. In some embodiments, the end 24 can be plugged in, such as with a suitable connector, plug, socket, etc., for electrical connection to the signal generator 14. In some other embodiments, depending on the needs of a particular application, the end 24 can be hardwired to the signal generator 14 in any suitable manner. In any case, in various embodiments, the controlled impedance network 18 is disposed towards the end 20 of the electrical wiring 12, and in some embodiments, can be disposed in the terminal 22.

[0032] In various embodiments, depending on the needs of a particular application, the signal generator 14 is any suitable one or more signal generators, such as an oscillator, a general signal generator, a function generator, a digital pattern generator, a radio frequency (RF) transmitter, etc. Depending on the needs of a particular application, the signal 16 generated by the signal generator 14 can be any suitable signal, such as but not limited to a sine wave, a square wave, a sawtooth wave, a step (pulse) wave, a triangular wave, a digital logic signal, combinations thereof, etc. In some embodiments, the signal generator 14 can be provided as a stand-alone self-contained instrument, as a component of a device, subsystem or system, and / or can be implemented as a digital signal processor configured to synthesize a waveform (the output of which can be input to a digital-to-analog converter (DAC) depending on the needs of a particular application).

[0033] In various embodiments, the signal generator 14 generates a signal 16 for testing the continuity of the electrical wiring 12. In some embodiments, the signal generator 14 generates only the signal 16. In some other embodiments, the signal generator 14 may be configured to generate signals other than the signal 16. In some such embodiments, if desired, the generation of any such additional signals may be disabled while the signal 16 is being generated.

[0034] In some embodiments, in addition to the signal 16, the electrical wiring 12 also carries at least one additional electrical signal. In some such embodiments, the signal generator 14 may generate the signal 16 and the additional signal. In some other such embodiments, the additional signal may be provided by a source other than the signal generator 14. Regardless of the source of the additional signal, in embodiments where the electrical wiring 12 carries an additional signal, it should be understood that the frequency of the signal 16 and the resulting component selection and frequency response of the controlled impedance network 18 are selected such that the signal 16 and the controlled impedance network 18 do not interfere with the additional signal. As will be described below, in various embodiments, interference between the signal 16 and the controlled impedance network 18 and the additional signal can be avoided by selecting the frequency of the signal 16 to be sufficiently different from one or more frequencies of the additional signal. When combined with an appropriate component selection and frequency response of the controlled impedance network 18, a frequency of the signal 16 that is sufficiently different from one or more frequencies of the additional signal can help enable the signal 16 to not interfere with the additional signal.

[0035] In various embodiments, the signal detector 26 includes any suitable signal detector selected for a particular application. In some embodiments, the signal detector 26 may include any suitable voltage detector (whether a separate instrument or a component of a device), any suitable analog signal detector, suitable digital electronic components configured to sample the signal 16, and the like.

[0036] In some embodiments, the signal generator 14 and / or the signal detector 26 may be controlled by a controller 28. In such embodiments, depending on the needs of a particular application, the controller 28 may include any suitable computer processor-based controller. Controllers are well known, and thus a description of the construction and operation of the controller 28 is not necessary for understanding the subject matter disclosed herein.

[0037] See also Figure 4A and Figure 5A , in some embodiments, the controlled impedance network 18 may include a low-pass filter 18A ( Figure 4A ), and in some other embodiments, the controlled impedance network 18 may include a notch filter 18B. These two illustrative and non-limiting embodiments will be discussed below.

[0038] AsFigure 4A As shown, in some embodiments, the controlled impedance network 18 includes a low-pass filter 18A disposed in the terminal 22. In such embodiments, the low-pass filter 18A includes a capacitor 30 electrically connected between the conductors of the electrical wiring 12.

[0039] It should be understood that the signal detector 26 measures the signal 16 after some impedance to observe the effect of the controlled impedance network 18 shorting the signal 16 effectively. To this end, in various embodiments, a resistor 31 is disposed between the output of the signal generator 14 and the node 33 where the signal detector 26 measures the signal 16.

[0040] In some embodiments, if desired, the low-pass filter 18A may also include an optional additional current-limiting resistor 32 disposed in series with the electrical wiring 12 in the terminal 22. In some other embodiments, the current-limiting resistance of the resistor 31 may be considered sufficient and the optional resistor 32 is not used.

[0041] As described above, in some embodiments, in addition to the signal 16, the electrical wiring 12 may also carry at least one additional electrical signal. It should be understood that in such embodiments, the signal 16 is generated when any additional electrical signals are disabled. In such embodiments, the low-pass filter 18A has a cut-off frequency f that is sufficiently higher than the highest frequency of the additional signals c , such that the low-pass filter 18A does not interfere with the additional signals. A non-limiting example of this situation will be discussed below by way of illustration only and not limitation.

[0042] As Figure 5A shown, in some embodiments, the controlled impedance network 18 includes a notch filter 18B disposed in the terminal 22. In such embodiments, the notch filter 18B includes a capacitor 34 electrically connected in series with an inductor 36. The series combination of the capacitor 34 and the inductor 36 is electrically connected between the conductors of the electrical wiring 12. The notch filter 18B has a stopband frequency range that has a center frequency f0 at which the impedance of the capacitor 34 and the impedance of the inductor 36 cancel each other out.

[0043] As described above, the signal detector 26 measures the signal 16 at the node 33 after the resistor 31 disposed between the output of the signal generator 14 and the node 33. In some embodiments, if desired, the notch filter 18B may also include an optional additional current-limiting resistor 38 disposed in series with the electrical wiring 12 in the terminal 22. In some other embodiments, the current-limiting resistance of the resistor 31 may be considered sufficient and the optional resistor 38 is not used.

[0044] As described above, in some embodiments, in addition to signal 16, electrical wiring 12 may also carry at least one additional electrical signal. Also as described above, in such embodiments, signal 16 is generated when any additional electrical signal is disabled. In some such embodiments where only one additional signal is provided, the center frequency f0 is sufficiently higher than the frequency of the additional signal such that notch filter 18B does not interfere with the additional signal. In some other such embodiments where two (or more) additional signals having different frequencies are provided, the center frequency f0 is between the different frequencies of the additional signals. A non-limiting example of this situation will be discussed below by way of illustration only and not limitation.

[0045] Regardless of whether any additional electrical signals are generated or whether the controlled impedance network 18 includes low-pass filter 18A or notch filter 18B, it should be understood that continuity (i.e., no break in electrical wiring 12 including the ground wire) can be distinguished from discontinuity (i.e., a break in electrical wiring 12 including the ground wire). Continuity is detected when signal 16 is injected and attenuated by the controlled impedance network 18 and the signal detector 26 measures the attenuated signal. Discontinuity is detected when signal 16 is injected and the signal detector 26 measures a full-strength signal with little, minimal, or no attenuation.

[0046] See also Figure 2 , Figures 3A to 3E , Figure 4B , Figure 4C , Figure 5B and Figure 5C , in various embodiments, the exemplary electric vehicle charging system 50 is capable of testing the continuity of electrical wiring without connecting the electrical wiring to the vehicle. It should be understood that the electric vehicle charging system 50 is provided by way of illustration only and not limitation.

[0047] As Figure 2 shown, in various embodiments, the electric vehicle charging system 50 includes a dispenser 52 configured to receive direct current (DC) power and distribute the DC power to the electric vehicle 54 via a cable 148 and a charge coupler 58. The charge coupler 58 is connected to the electric vehicle 54 via a vehicle interface 60. As will be described below, in various embodiments, when the charge coupler 58 is disconnected from the vehicle interface 60, the continuity of the wiring in the cable 148 carrying the control pilot signal can be tested.

[0048] As Figure 3A shown and by way of non-limiting example, in various embodiments, the charging system 50 includes a power cabinet 112 having at least one direct current (DC) power module 114. The power distributor 52 is electrically coupled to the power cabinet 112. The charge coupler 58 is configured to distribute DC power.

[0049] Also as Figure 3A shown, in various embodiments, the power cabinet 112 has a main controller 126 coupled to a communication hub 128. At least one DC power module 114 converts alternating current (AC) power from an AC power input 130, which passes through a main circuit breaker 132 and then is sent to the DC power module 114 and a distributor power module 134 that provides operating power to various electronics in the distributor 52.

[0050] In various embodiments, the power cabinet 112 may include up to five (5) DC power modules 114. It should be understood that in various embodiments, the power cabinet 112 may suitably include, but is not limited to, an EVSE power cabinet. However, it should be understood that each power cabinet 112 may include any number of DC power modules 114 depending on the needs of a particular application. In various embodiments, an output conduit 115 electrically connects each DC power module 114 to an associated power distributor 52 that is configured to provide power to a vehicle 54.

[0051] In various embodiments, the main controller 126 is configured to control the power output of each DC power module 114. In various embodiments, the power cabinet 112 may use isolated power modules 114 combined to achieve a peak power output of over 300 kW. In such embodiments, the power cabinet 112 has the ability to charge over 20 vehicles in an overnight stay scenario.

[0052] As Figure 3B shown, in various embodiments, the distributor 52 includes a conduit input 136, a controller 138, a power supply 140, a charge coupler 58, and a switch unit 142. The switch unit 142 includes switches 142A and 142B. The switch unit 142 may be controlled by the controller 138. The controller 138 and the switch unit 142 are configured to control (via switch 142A) the provision of control signals to and from the charge coupler 58 and (via switch 142B) the provision of power to the charge coupler 58.

[0053] In various embodiments, the main controller 126 ( Figure 3A) can be configured to generate control signals 144A, 144B, 144C, 144D, and 144E for the controller 138 of the dispenser 52, thereby controlling the power output to each dispenser 52. Similarly, although five control signals are shown in this non-limiting example, it should be understood that any number of dispensers 58 and associated control signals can be used according to the needs of a particular application. The communication hub 128 can be configured to provide the control signals 144A, 144B, 144C, 144D, and 144E from the master controller 126 to the controller 138. The communication hub 128 can also be configured to have a communication network connection that can be wired or wireless. Each dispenser 58 can be individually addressed by the communication hub 128. Each dispenser 58 can also have an associated dispenser identifier to facilitate communication between the controller 138 and the communication hub 128 (such as, but not limited to, information about the status of the continuity of the electrical wiring 12 of any given dispenser 58).

[0054] In various embodiments, the charge coupler 58 includes a housing 62. A DC contact 64 is disposed in the housing 62 and is configured to be electrically coupled to distribute DC power to the electric vehicle 54( Figure 2 ). In such embodiments, the electrical wiring 12 includes a control pilot wire 66 disposed in the housing 62( Figure 3C ). As will be discussed below, the control pilot wire 66 is configured to receive a control pilot signal having a first frequency for low-level signaling, a power line communication signal having a second frequency range for high-level communication, and a continuity check signal having a third frequency different from the first frequency and the second frequency range. A ground wire 68( Figure 3C ) is disposed in the housing 62 and is configured to be electrically connectable to an equipment ground. A controlled impedance network 18 is electrically connected between the control pilot wire 66 and the ground wire 68. As will be described below, the controlled impedance network 18 is configured to attenuate the continuity check signal.

[0055] As Figure 3CAs shown, the dispenser 52 includes a signal generator 14. It should be understood that the signal generator 14 may include more than one signal generator depending on the needs of a particular application. The signal generator 14 is configured to generate a control pilot signal 70 having a first control pilot for low-level signaling, a power line communication signal 71 having a second frequency range for high-level communication, and a continuity check signal 16 having a third frequency different from the first frequency and the second frequency range. It should be understood that in various embodiments, the continuity check signal 16 may be generated and injected onto the electrical wiring 12 while disabling the generation of the control pilot signal 70 and the power line communication signal 71. The signal detector 26 is configured to detect the continuity check signal 16. The cable assembly 148 includes a control pilot line 66 and a ground line 68, the control pilot line being electrically coupled to receive the control pilot signal 70, the power line communication signal 71, the continuity check signal 16, and the ground line being capable of being electrically connected to an equipment ground. The charge coupler 58 is coupled to the end of the cable assembly 148. The charge coupler 58 includes a housing 62. A controlled impedance network 18 is disposed in the housing 62 and is electrically connected between the control pilot line 66 and the ground line 68. The controlled impedance network 18 is configured to attenuate the continuity check signal 16.

[0056] The signal detector 26 measures the signal 16 at node 33 after a resistor 31 disposed between the output of the signal generator 14 and node 33. In some embodiments, the resistor 31 suitably has a value of 1KΩ in accordance with SAE JI772.

[0057] As Figure 3D shown, the control pilot signal 70 is provided by the signal generator 14 and is injected onto the electrical wiring 12. The electrical wiring 12 is the main control wire and is connected to an equipment ground through a control circuit (not shown) on the vehicle. The control pilot signal 70 performs the following functions: (i) verifying the presence and connection of the vehicle; (ii) preventing the power supply from being energized / de-energized; (iii) transmitting the supply device current rating to the vehicle; (iv) monitoring the presence of the equipment ground; and (v) establishing vehicle ventilation requirements.

[0058] In various embodiments, the control pilot signal 70 has a first control pilot for low-level signaling. The low-level signaling component of the control pilot signal 70 is suitably a square wave signal which, according to SAE JI772, has a frequency of approximately 1 KHz and peak voltages of +12V and -12V. In various embodiments, the control pilot signal 70 can be pulse width modulated between 0% and 100%. According to SAE J1772, the low-level signaling component of the control pilot signal 70 conveys information about the vehicle / EVSE state of the charging sequence (i.e., state A (vehicle not connected), state Bl (vehicle connected but not ready to receive energy, EVSE not ready to supply energy), state B2 (vehicle connected but not ready to receive energy, EVSE capable of supplying energy), state C (vehicle connected and ready to receive energy, no indoor charging air ventilation required, EVSE capable of supplying energy), state D (vehicle connected and ready to receive energy, indoor charging air ventilation required, EVSE capable of supplying energy), state E (EVSE disconnected from vehicle and utility, EVSE has lost utility power or control pilot shorted to control pilot reference) and state F (other EVSE problems)). The voltage levels correspond to the states (+12V at 100% duty cycle = A, +9V = B1, and B2 + 6V with pulse width modulation), and the duty cycle from 9.5% to 96.5% indicates the maximum current provided by the EVSE (6A up to 80A). A 5% duty cycle indicates a digital communication request from the EVSE to the electric vehicle.

[0059] This initiates high-level communication via power line communication (PLC) through the power line communication signal 71, as described below.

[0060] As described above, a 5% duty cycle indicates a digital communication request from the EVSE to the electric vehicle. This initiates high-level communication via power line communication (PLC) (such as but not limited to via the HomePlug Green PHY communication protocol) through the power line communication signal 71. Thus, it should be understood that both the control pilot signal 70 and the power line communication signal 71 are injected onto the same electrical wiring 12 and are sometimes injected simultaneously. In any case, it should be understood that in various embodiments, a continuity check signal 16 can be generated and injected onto the electrical wiring 12 while disabling the generation of the control pilot signal 70 and the power line communication signal 71.

[0061] As Figure 3EAs shown, in various embodiments, according to ISO 15118, the power line communication signal 71 is a broadband signal with a second frequency range for high-level communication. In various embodiments, the power line communication signal 71 is suitably a broadband power line communication signal between 2 MHz and 28 MHz, which modulates the power line communication signal 71 onto a suitable HomePlug carrier signal using HomePlug Green PHY power line communication technology. HomePlug Green PHY communication operates independently of the 1 kHz control pilot signal 70. Thus, it should be understood that in various embodiments, the control pilot signal 70 and the power line communication signal 71 are simultaneously injected onto the electrical wiring 12.

[0062] It should be understood that the power line communication signal 71 provides a Signal Level Attenuation Characterization (SLAC) protocol (to measure the signal strength of the signal between HomePlug Green PHY stations) and ISO 15118 messages (i.e., an application layer message set designed to support energy transfer from the EVSE to the EV; also known as V2G messages).

[0063] As Figures 4A to 4C shown, in some embodiments, the controlled impedance network 18 includes a low-pass filter 18A. As Figure 4B shown, the cut-off frequency f c is higher than the frequency of the low-level signaling control pilot signal 70 (as shown by line 72 at 1 KHz) and the frequency range of the high-level communication signal 71 (as shown by the region 74 between 2 MHz and 28 MHz). In a non-limiting example given by way of illustration only, the cut-off frequency f c is approximately 159 MHz, and the capacitor 30 has a value of approximately 1 pF. As described above, according to SAE JI772, the resistor 31 has a value of 1 KΩ. In some embodiments, the current-limiting resistance of the resistor 31 may be considered sufficient, and the optional resistor 32 is not used. However, in some other embodiments, the optional resistor 32 may be suitably used according to the needs of a particular application.

[0064] It should be understood that the cut-off frequency f c of approximately 159 MHz is sufficiently higher than the highest frequency in the control pilot signal 70 or the high-level communication signal 71 such that the low-level signaling control pilot signal 70 and the high-level communication signal 71 will not be affected by the low-pass filter 18A. Instead, the signal 16 (which is suitably a signal having at least the same cut-off frequency f cAny signal at the same high frequency) will be sufficiently attenuated so as not to interfere with the low-level signaling control pilot signal 70 or the high-level communication signal 71. By way of non-limiting example, in various embodiments, the signal 16 may have a frequency of about 800 KHz. In some such embodiments, and again by way of non-limiting example, the signal 16 may have a frequency of about 795.7 KHz.

[0065] As Figure 4B shown, it should be understood that the higher the frequency of the signal 16, the greater the attenuation of the signal 16 by the low-pass filter 18A. It should also be understood that the passive single-pole low-pass filter 18A is given by way of illustration only and not limitation. For example, in various embodiments, the low-pass filter 18A may be a passive filter having more than a single pole. Also, in various other embodiments, the low-pass filter 18A may be an active low-pass filter according to the needs of a particular application.

[0066] As Figures 5A to 5E shown, in some embodiments, the controlled impedance network 18 includes a notch filter 18B. As Figure 5B shown, the center frequency f0 is between the frequency of the low-level signaling control pilot signal 70 (as shown by line 72 at 1 KHz) and the frequency range of the high-level communication signal 71 (as shown by the region 74 between 2 MHz and 28 MHz). In a non-limiting example given by way of illustration only, the center frequency f0 is about 795.7 KHz, the capacitor 34 has a value of about 200 pF, and the inductor 36 has a value of 200 μH. As described above, according to SAE J1772, the resistor 31 has a value of 1 KΩ. In some embodiments, the current-limiting resistor of the resistor 31 may be considered sufficient and the optional resistor 38 is not used. However, in some other embodiments, the optional resistor 38 may be appropriately used according to the needs of a particular application.

[0067] It should be understood that the center frequency f of about 795.7 KHz c is sufficiently higher than the 1 KHz frequency of the low-level signaling component of the control pilot signal 70 and sufficiently lower than the lowest frequency (2 MHz) of the high-level communication component of the control pilot signal 70 such that the low-level signaling component and the high-level communication component of the control pilot signal 70 will not be affected by the notch filter 18B. In contrast, the signal 16 (which is suitably at a frequency close to the cut-off frequency f cAny signal) will be sufficiently attenuated so as not to interfere with the low-level signaling component of the control pilot signal 70 and the high-level communication component of the control pilot signal 70. As described above and by way of non-limiting example, in various embodiments, the signal 16 may have a frequency of approximately 800 KHz. In some such embodiments, and again by way of non-limiting example, the signal 16 may have a frequency of approximately 795.7 KHz.

[0068] As Figure 5D and Figure 5E shown, it should be understood that the higher the quality factor Q of the notch filter 18B, the higher the selectivity

[0069] where

[0070] ω o is the center frequency f c of the wavelength

[0071] R is the resistance of the resistor 38

[0072] C is the capacitance of the capacitor 34

[0073] L is the inductance of the inductor 36

[0074] That is, a higher quality factor Q results in a narrower stopband and a steeper transition to the passband.

[0075] It should also be understood that the passive second-order notch filter 18B is given by way of illustration and not limitation. For example, in various embodiments, the notch filter 18B may be a passive filter of a higher order than a second-order notch filter. As another example, in various other embodiments, depending on the needs of a particular application, the notch filter 18B may be an active notch filter.

[0076] Regardless of whether the controlled impedance network 18 includes the low-pass filter 18A or the notch filter 18B, it should be understood that continuity (i.e., no break in the electrical wiring 12 including the ground wire) can be distinguished from discontinuity (i.e., a break in the electrical wiring 12 including the ground wire). Continuity is detected when the signal 16 is injected and attenuated by the controlled impedance network 18 and the signal detector 26 measures the attenuated signal. Discontinuity is detected when the signal 16 is injected and the signal detector 26 measures a full-strength signal with little, minimal, or no attenuation.

[0077] Those skilled in the art will recognize that at least a portion of the apparatus and / or processes described herein can be integrated into a data processing system. Those skilled in the art will recognize that a data processing system typically includes one or more of the following: a system unit housing, a video display device, memory (such as volatile or non-volatile memory), a processor (such as a microprocessor or digital signal processor), a computing entity (such as an operating system), drivers, a graphical user interface and applications, one or more interaction devices (e.g., a touchpad, a touch screen, an antenna, etc.) and / or a control system including feedback loops and control motors (e.g., for sensing position and / or velocity feedback; control motors for moving and / or adjusting components and / or quantities). A data processing system can be implemented using suitable commercially available components, such as those commonly found in data computing / communication and / or network computing / communication systems.

[0078] As used in the foregoing / foregoing disclosure, the term module can refer to a collection of one or more components arranged in a particular manner, or a collection of one or more general-purpose components that can be configured to operate in a particular manner at one or more particular points in time and / or further configured to operate in one or more additional manners at one or more additional times. For example, the same hardware or the same portion of hardware can be configured / reconfigured in sequential / parallel time as a first type of module (e.g., at a first time), a second type of module (e.g., at a second time, which in some cases can coincide with, overlap, or be after the first time), and / or a third type of module (e.g., at a third time, which in some cases can coincide with, overlap, or be after the first time and / or the second time), etc. Reconfigurable and / or controllable components (e.g., general-purpose processors, digital signal processors, field-programmable gate arrays, etc.) can be configured as a first module for a first purpose, then configured as a second module for a second purpose, then configured as a third module for a third purpose, etc. The transition of reconfigurable and / or controllable components can occur in as little as a few nanoseconds, or can occur over a period of minutes, hours, or days.

[0079] In some such examples, when a component is configured to perform a second purpose, it may no longer be able to perform that first purpose until it is reconfigured. The component can switch between configurations as different modules in as little as a few nanoseconds. The component can be reconfigured dynamically. For example, the reconfiguration of the component from a first module to a second module can occur right when the second module is needed. The component can be reconfigured in stages. For example, parts of the first module that are no longer needed can be reconfigured into the second module, even before the first module has completed its operation. Such reconfiguration can occur automatically or can be prompted by an external source, whether that source is another component, an instruction, a signal, a condition, an external stimulus, or the like.

[0080] For example, the central processing unit of a personal computer can operate at various times as a module for displaying graphics on a screen, a module for writing data to a storage medium, a module for receiving user input, and a module for multiplying two large prime numbers by configuring its logic gates according to its instructions. Such reconfiguration may not be visible to the naked eye and can include, in some embodiments, the activation, deactivation, and / or rerouting of various parts of the component (e.g., switches, logic gates, inputs, and / or outputs). Thus, in the examples present in the foregoing / foregoing disclosure, if the example includes or recites multiple modules, the example includes the possibility that the same hardware can implement more than one of the recited modules simultaneously or at discrete times or timings. Whether using more components, fewer components, or the same number of components as the number of modules, the implementation of multiple modules is merely an implementation choice and generally does not affect the operation of the modules themselves. Thus, it should be understood that any recitation in this disclosure of multiple discrete modules includes implementing these modules as any number of underlying components, including but not limited to a single component that reconfigures itself over time to perform the functions of multiple modules and / or multiple components that are similarly reconfigured, and / or a dedicated reconfigurable component.

[0081] In some cases, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable as,” “adapted to,” “capable of,” “conformable to,” etc. Those skilled in the art will recognize that such terms (e.g., “configured to”) generally encompass components in an active state and / or a passive state and / or a standby state, unless the context requires otherwise.

[0082] While specific aspects of the subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based on the teachings herein, changes and modifications can be made without departing from the subject matter described herein and its broader aspects. Accordingly, the appended claims are intended to cover all such changes and modifications within their scope, as in the true spirit and scope of the subject matter described herein. Those skilled in the art should understand that, generally speaking, the terms used herein, particularly the terms used in the appended claims (e.g., the body of the appended claims), are generally intended to be "open" terms (e.g., the term "comprising" should be interpreted as "including but not limited to", the term "having" should be interpreted as "having at least", the term "containing" should be interpreted as "containing but not limited to", etc.). Those skilled in the art should further understand that if the intention is to introduce a specific number of recited claims, such intention will be explicitly recited in the claims, and in the absence of such recitation, there is no such intention. For example, for purposes of illustration, the following appended claims may contain the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as implying that the introduction of a claim recitation by the indefinite article "a" or "an" limits any particular claim containing such introduced claim recitation to a claim containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and the indefinite article such as "a" or "an" (e.g., "a" and / or "an" should generally be interpreted as meaning "at least one" or "one or more"); this also applies to the use of the definite article used to introduce a claim recitation. In addition, even if a specific number of introduced claim recitations are explicitly recited, those skilled in the art will recognize that such recitation will generally be interpreted as meaning at least the recited number (e.g., merely reciting "two recitations" without further qualification generally means at least two recitations, or two or more recitations). Further, in those instances where a convention similar to "at least one of A, B, and C, etc." is used, generally speaking, the meaning intended by such construction will be understood by those skilled in the art (e.g., "a system having at least one of A, B, and C" will include, but not be limited to, a system having A alone, having B alone, having C alone, having A and B, having A and C, having B and C, and / or A, B, and C, etc.). Those skilled in the art will further understand that, unless the context dictates otherwise, a disjunctive word and / or phrase presenting two or more alternative terms (whether in the specification, claims, or drawings) will generally be understood to contemplate the possibility of including one of the terms, any one of the terms, or both terms. For example, the phrase "A or B" will generally be understood to include the possibilities of "A" or "B" or "A and B".

[0083] The above detailed embodiments have illustrated various embodiments of the apparatus and / or process by using block diagrams, flowcharts, and / or examples. In cases where such block diagrams, flowcharts, and / or examples contain one or more functions and / or operations, those skilled in the art will understand that each function and / or operation within such block diagrams, flowcharts, or examples can be implemented individually and / or jointly by a wide range of hardware, software (e.g., a high-level computer program used as a hardware specification), firmware, or nearly any combination thereof that is limited to patentable subject matter under 35 U.S.C. 101. In an embodiment, several parts of the subject matter described herein can be implemented via application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), digital signal processors (DSPs), or other integrated formats. However, those skilled in the art will recognize that some aspects of the embodiments disclosed herein can be equivalently implemented in integrated circuits as one or more computer programs (e.g., one or more programs running on one or more computer systems), one or more programs running on one or more processors (e.g., one or more programs running on one or more microprocessors), firmware, or nearly any combination thereof that is limited to patentable subject matter under 35 U.S.C. 101, and according to the present disclosure, designing the circuitry and / or writing the code for the software (e.g., a high-level computer program used as a hardware specification) and / or firmware will be entirely within the skill of those in the art. Additionally, those skilled in the art will understand that the mechanisms of the subject matter described herein can be distributed as a program product in a variety of forms, and the exemplary embodiments of the subject matter described herein apply regardless of the specific type of signal-bearing medium used for actual distribution. Examples of signal-bearing media include, but are not limited to, the following: recordable media such as floppy disks, hard disk drives, optical discs (CDs), digital video discs (DVDs), digital tapes, computer memories, etc.; and transmission media such as digital and / or analog communication media (e.g., fiber optic cables, waveguides, wired communication links, wireless communication links (e.g., transmitters, receivers, transmission logic, reception logic, etc.), etc.).

[0084] Relative to the appended claims, those skilled in the art will understand that the operations recited therein can generally be performed in any order. Additionally, although the various operation flows are presented in sequence, it should be understood that the various operations can be performed in other orders than the order shown or can be performed simultaneously. Unless the context otherwise requires, examples of such alternative orderings can include overlapping, interleaving, interrupting, reordering, incrementing, preparatory, supplementary, simultaneous, reverse, or other variant orderings. Moreover, unless the context otherwise requires, terms such as "in response to," "associated with," or other past-tense adjectives are not generally intended to exclude such variants.

[0085] While the subject matter disclosed herein has been described with reference to illustrative embodiments, those of ordinary skill in the art will understand that various modifications may be made without departing from the scope of the claimed subject matter.

Claims

1. An electric vehicle charging system, the electric vehicle charging system comprising: A distributor configured to receive and distribute direct current (DC) power, the distributor comprising: At least one signal generator configured to generate a control pilot signal having a first frequency for low-level signaling, a power line communication signal having a second frequency range for high-level communication, and a continuity check signal having a third frequency different from the first frequency and the second frequency range; A signal detector configured to detect the continuity check signal; A cable assembly comprising a control pilot line and a ground wire, the control pilot line being electrically coupled to receive the control pilot signal, the power line communication signal, and the continuity check signal, the ground wire being electrically connectable to an equipment ground; and A charge coupler coupled to an end of the cable assembly, the charge coupler comprising: A housing; and A controlled impedance network disposed in the housing and electrically connected between the control pilot line and the ground wire, the controlled impedance network being configured to attenuate the continuity check signal.

2. The charging system according to claim 1, wherein the controlled impedance network comprises a low-pass filter.

3. The charging system according to claim 2, wherein the low-pass filter has a cut-off frequency higher than the first frequency and the second frequency range.

4. The charging system according to claim 1, wherein the controlled impedance network comprises a notch filter.

5. The charging system according to claim 4, wherein the notch filter has a stopband frequency range having a center frequency between the first frequency and the second frequency range.

6. The charging system according to claim 1, wherein the first frequency is 1 KHz, and the second frequency range is between 2 MHz and 28 MHz.

7. A charge coupler for an electric vehicle charging system, the charge coupler configured to be connectable to an electric vehicle for charging, the charge coupler comprising: A housing; DC contacts disposed in the housing and configured to be electrically coupled to distribute DC power to the electric vehicle; A control pilot line disposed in the housing, the control pilot line being configured to receive a control pilot signal having a first frequency for low-level signaling, a power line communication signal having a second frequency range for high-level communication, and a continuity check signal having a third frequency different from the first frequency and the second frequency range; A ground wire disposed in the charge coupler housing, the ground wire being configured to be electrically connectable to an equipment ground; and A controlled impedance network electrically connected between the control pilot line and the ground wire, the controlled impedance network being configured to attenuate the continuity check signal to test wiring continuity when the charge coupler is disconnected from the electric vehicle.

8. The charge - coupled device according to claim 7, wherein the controlled impedance network includes a low - pass filter.

9. The charge - coupled device according to claim 8, wherein the low - pass filter has a cut - off frequency higher than the first frequency and the second frequency range.

10. The charge - coupled device according to claim 7, wherein the controlled impedance network includes a notch filter.

11. The charge - coupled device according to claim 10, wherein the notch filter has a stop - band frequency range, and the stop - band frequency range has a center frequency between the first frequency and the second frequency range.

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