Methods and mechanisms for monitoring charging port functionality

Abstract

A vehicle is configured to perform one or more methods for detecting a charging socket during a charging cycle. The method includes: providing a charging current through a pin; monitoring a pin temperature during the charging current; and applying a first step function to the charging current. The method may further include: monitoring a first step change in the pin temperature during the first step function; comparing the first step change in the pin temperature with the first expected temperature change to generate a first deviation; and comparing the first deviation with the predetermined threshold. If the first deviation exceeds the predetermined threshold, a maintenance alarm is signaled, and if the first deviation is less than the predetermined threshold, the first deviation is recorded.

Description

Technical Field

[0001] This disclosure relates to methods and mechanisms for determining the functionality of a vehicle with charging capability or assessing its health status, such as plug-in hybrid vehicles and electric vehicles. Summary of the Invention

[0002] A vehicle is provided, configured to perform one or more methods for detecting a charging socket during a charging cycle. The method includes: providing a charging current through a pin; monitoring a pin temperature during the charging current; and applying a first step function to the charging current. The method further includes: monitoring a first step change in the pin temperature during the first step function; comparing the first step change in the pin temperature with the first expected temperature change to generate a first deviation; and comparing the first deviation with the predetermined threshold. If the first deviation exceeds the predetermined threshold, a maintenance alarm is signaled, and if the first deviation is less than the predetermined threshold, the first deviation is recorded.

[0003] The method may include: applying a second step function to the charging current; monitoring a second step change in the pin temperature during the second step function; comparing the second step change in the pin temperature with a second expected temperature change to generate a second deviation; and comparing the second deviation with a predetermined threshold. If the second deviation exceeds the predetermined threshold, a maintenance alarm is signaled, and if the second deviation is less than the predetermined threshold, the second deviation is recorded.

[0004] The use of the first step function can be scheduled so that it does not occur during each charging cycle. One or more step functions can be scheduled based on vehicle history, so that detection of pin functionality only occurs during extended charging cycles. The first expected temperature change can be calculated based on a formula that makes the stored energy equal to the difference between the outflow and inflow energy plus the energy generated, and / or can be calculated according to a physics-based thermal model.

[0005] The present invention also includes the following solutions:

[0006] Option 1. A method for detecting the functionality of multiple pins in a vehicle's charging socket during a charging cycle, comprising:

[0007] The charging current is provided through the pin;

[0008] The pin temperature of the pin is monitored during the charging current.

[0009] Apply the first step function to the charging current;

[0010] During the first step function, monitor the first step change in the pin temperature;

[0011] The first step change in the pin temperature is compared with a first expected temperature change to generate a first deviation; and

[0012] Compare the first deviation with a predetermined threshold:

[0013] If the first deviation exceeds the predetermined threshold, a maintenance alarm signal is issued, and

[0014] If the first deviation is less than the predetermined threshold, then the first deviation is recorded.

[0015] Option 2. The method according to Option 1 further includes:

[0016] The second step function is applied to the charging current;

[0017] During the second step function, monitor the second step change in the pin temperature;

[0018] The second step change in the pin temperature is compared with the second expected temperature change to generate a second deviation; and

[0019] Compare the second deviation with the predetermined threshold:

[0020] If the second deviation exceeds the predetermined threshold, a maintenance alarm signal is issued, and

[0021] If the second deviation is less than the predetermined threshold, then the second deviation is recorded.

[0022] Option 3. The method according to Option 1 further includes:

[0023] The first step function is scheduled so that it does not occur during each charging cycle.

[0024] Option 4. The method according to Option 3 further includes:

[0025] The first step function is scheduled based on vehicle history, so that the detection of the pin's function occurs during the extended charging cycle.

[0026] Option 5. The method according to Option 1 further includes:

[0027] The first expected temperature change is calculated based on a formula that equals the difference between the outflow and inflow energy plus the energy generated.

[0028] Option 6. The method according to Option 5 further includes:

[0029] The first expected temperature change is calculated based on a physics-based thermal model.

[0030] Option 7. The method according to Option 2 further includes:

[0031] The first and second step functions are scheduled based on vehicle history.

[0032] Wherein the first step function and the second step function do not occur during each charging cycle, and

[0033] The function of the pin is detected during the extended charging cycle.

[0034] Option 8. A vehicle comprising:

[0035] Rechargeable energy storage system (RESS) that selectively undergoes charging cycles;

[0036] A charging socket with multiple pins;

[0037] A controller, which communicates with the RESS and the charging socket, is configured to detect the functionality of the charging socket during the charging cycle by:

[0038] The charging current is provided through the pin;

[0039] The pin temperature of the pin is monitored during the charging current.

[0040] Apply the first step function to the charging current;

[0041] During the first step function, monitor the first step change in the pin temperature;

[0042] The first step change in the pin temperature is compared with a first expected temperature change to generate a first deviation; and

[0043] Compare the first deviation with a predetermined threshold:

[0044] If the first deviation exceeds the predetermined threshold, a maintenance alarm signal is issued, and

[0045] If the first deviation is less than the predetermined threshold, then the first deviation is recorded.

[0046] Option 9. The vehicle according to Option 8, wherein the controller is further configured to detect the function of the charging socket during the charging cycle by:

[0047] The second step function is applied to the charging current;

[0048] During the second step function, monitor the second step change in the pin temperature;

[0049] The second step change in the pin temperature is compared with a second expected temperature change to generate a second deviation; and

[0050] Compare the second deviation with the predetermined threshold:

[0051] If the second deviation exceeds the predetermined threshold, a maintenance alarm signal is issued, and

[0052] If the second deviation is less than the predetermined threshold, then the second deviation is recorded.

[0053] Option 10. The vehicle according to Option 8, wherein the controller is further configured to detect the function of the charging socket during the charging cycle by:

[0054] The first step function is scheduled so that it does not occur during each charging cycle.

[0055] Option 11. The vehicle according to Option 10, wherein the controller is further configured to detect the function of the charging socket during the charging cycle by:

[0056] The first step function is scheduled based on vehicle history, so that the function of the pin is detected during the extended charging cycle.

[0057] Option 12. The vehicle according to Option 8, wherein the controller is further configured to detect the function of the charging socket during the charging cycle by:

[0058] The first expected temperature change is calculated based on a formula that equals the difference between the outflow and inflow energy plus the energy generated.

[0059] Option 13. The vehicle according to Option 12, wherein the controller is further configured to detect the function of the charging socket during the charging cycle by:

[0060] The first expected temperature change is calculated based on a physics-based thermal model.

[0061] Option 14. The vehicle according to Option 9, wherein the controller is further configured to detect the function of the charging socket during the charging cycle by:

[0062] The first and second step functions are scheduled based on vehicle history.

[0063] Wherein the first step function and the second step function do not occur during each charging cycle, and

[0064] The function of detecting the pin during the extended charging cycle.

[0065] Option 15. The vehicle according to Option 8 further includes:

[0066] The lock on the charging socket prevents the initiation of the charging cycle unless it is successfully locked to the corresponding structure.

[0067] The foregoing features and advantages of this disclosure, as well as other features and advantages, will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, of the best mode for carrying out this disclosure. Attached Figure Description

[0068] Figure 1 It is a schematic diagram of a vehicle having one or more rechargeable energy storage systems (RESS) electrically connected to at least one charging socket.

[0069] Figure 2A This is a schematic diagram of the charging current applied through the charging socket.

[0070] Figure 2B The pins inside the charging socket are subjected to... Figure 2A A schematic diagram of temperature measurement at the illustrative charging current.

[0071] Figure 3 This is a schematic diagram of a flowchart used to determine the health status of a charging socket.

[0072] Figure 4 This is a schematic diagram of a charging socket with one or more fault pins. Detailed Implementation

[0073] Referring to the accompanying drawings, the same reference numerals denote similar parts whenever possible. All descriptions in the drawings are also referenced to all other drawings. Figure 1 A portion of vehicle 10 is schematically shown, and is highly schematically illustrated. The vehicle may be, for example, but not limited to, an electric vehicle or a hybrid electric vehicle. Vehicle 10 includes a rechargeable energy storage system (RESS) 12, which may include, for example, but not limited to, a rechargeable battery or a rechargeable battery pack.

[0074] The control system or controller 14 is operatively communicable with necessary components of the vehicle 10 to perform the methods, algorithms, and health assessments described herein. The controller 14 includes, for example, but not limited to, a non-general-purpose electronic control device having a pre-programmed digital computer or processor, memory or non-transitory computer-readable medium for storing data such as control logic, instructions, lookup tables, etc., and multiple input / output peripherals, ports, or communication protocols. The controller 14 is configured to execute or implement any and all of the control logic or instructions described herein.

[0075] Furthermore, controller 14 may include or communicate with multiple sensors, including but not limited to those sensors configured to sense or estimate ambient temperature outside vehicle 10, various coolant temperatures inside vehicle 10, and other sensing capabilities. Controller 14 may be dedicated to a specific aspect of vehicle 10 described herein, or controller 14 may be part of a larger control system that manages many functions of vehicle 10.

[0076] The accompanying drawings and figures presented herein are illustrative, not to scale, and are provided for descriptive and support purposes only. Therefore, any specific or relative dimensions or alignments shown in the drawings should not be construed as limiting. While this disclosure may be illustrative with respect to a particular application or industry, those skilled in the art will recognize its broader applicability. Those skilled in the art will recognize that terms such as “above,” “below,” “up,” and “down” are used to describe the drawings and do not imply a limitation on the scope of this disclosure as defined by the appended claims. Any numerical designations, such as “first” or “second,” are illustrative only and are not intended to limit the scope of this disclosure in any way. Any use of the term “or,” whether in the specification or the claims, includes any specific element referenced and any combination of referenced elements, unless otherwise expressly stated.

[0077] A feature shown in one figure may be combined with, replaced by, or modified by a feature shown in any figure. Unless otherwise stated, no feature, element, or limitation is mutually exclusive with any other feature, element, or limitation. Furthermore, no feature, element, or limitation is absolutely necessary for operation. Any particular configuration shown in the figures is merely illustrative and does not limit the claims or description.

[0078] All numerical values ​​of parameters (e.g., quantities or conditions) in this specification, including the appended claims, should in all cases be understood to be modified by the term "about / approximately," regardless of whether the term actually appears before the numerical value. "About / approximately" indicates that the numerical value allows for some slight imprecision (a value that is somewhat close to the exact value; approximately or reasonably close to the value; almost). If the imprecision provided by "about / approximately" cannot be otherwise understood in this common sense in the art, then "about / approximately" as used herein at least indicates variations that may arise from common methods of measuring and using these parameters. Furthermore, the disclosure of scope includes the disclosure of all values ​​and the scope further subdivided throughout the scope. Each value within the scope and the endpoints of the scope are disclosed herein as separate embodiments.

[0079] When used, the term "substantially / approximately" refers to an ideal, perfect, or complete relationship, but where manufacturing reality prevents absolute perfection. Therefore, "substantially / approximately" indicates a typical difference from perfection. For example, if height A is substantially equal to height B, it might be preferable that the two heights are 100.0% equal, but manufacturing reality may cause the distance to differ from this perfection. Those skilled in the art will recognize acceptable amounts of variation. For example, but not limited to, coverage, area, or distance can typically be within exactly 10%. Similarly, relative alignments, such as parallel or perpendicular, can generally be considered within 5%.

[0080] Vehicle 10 includes a communication system 16 that is capable of sharing information determined by, for example, controller 14 or other components of vehicle 10 with locations outside vehicle 10. For example, but not limited to, communication system 16 may include cellular or Wi-Fi technology that allows signals to be transmitted to a centralized location such as cloud storage or communication networks.

[0081] The coolant circuit 20 or coolant system is in communication with RESS 12 and includes at least one pump 22. If the vehicle 10 also includes an internal combustion engine, the coolant circuit 20 may also pass through the internal combustion engine, or a separate coolant system may exist for other components of the vehicle 10.

[0082] The charging socket 30, having multiple pins 32, communicates with at least the controller 14 and the RESS 12. The charging socket 30 typically collaborates with a charging station via a charging cable, neither of which is shown. The charging cable may include some or all of the features corresponding to the pins 32. The charging socket 30 is also connected to the coolant circuit 20.

[0083] The example charging socket 30 shown has a total of seven pins 32, some of which may not be visible in the diagram. (Upper group (relative to...)) Figure 1 ) is used for AC charging, while the lower group (relative to) Figure 1This is for DC charging. Note that not all pins 32 are available for carrying charging current, as some are used for communication and / or control of the charging current flowing from the charging station through the charging socket 30. Additionally, note that different charging ports can be used with the methods and mechanisms described herein, including those with additional or fewer pins in total. For example, but not limited to, nine-pin or five-pin sockets can be used, and sockets with only AC or only DC connection capabilities can be used.

[0084] Several temperature measuring devices are embedded in or near the charging socket 30, so that the temperature of one or more pins 32 can be monitored and transmitted to the controller 14. For example, but not limited to, thermocouples may be placed near some or all of the pins 32.

[0085] The charging socket 30 includes a locking mechanism or lock 40 that can cooperate with a corresponding locking mechanism on the charging cable. Note that not all charging stations or charging sockets 30 will include lock 40 or a corresponding mechanism.

[0086] Now for reference Figure 2A and Figure 2B The accompanying drawings, with reference to other figures, illustrate a mechanism, method, or algorithm for testing and / or detecting the functionality of the charging socket 30. Figure 2A A schematic current graph 50 is shown, where the y-axis represents current 51 and the x-axis represents time 52. Current graph 50 shows the current flowing through the charging socket 30 while undergoing charging current.

[0087] like Figure 2A As shown, the charging current, which may be referred to as the baseline charging current 54, is provided through pin 32. During this time, vehicle 10 undergoes a charging cycle suitable for recharging RESS 12. Controller 14 also monitors the pin temperature of pin 32, at least while the charging current is applied. Controller 14, or another control system managing the charging cycle, applies a first step function 56 to the charging current. Note that the baseline charging current 54 can be zero or non-zero. When the baseline charging current 54 is zero, the health assessment described herein can occur before the start of the charging cycle.

[0088] Figure 2B A schematic temperature curve 60 is shown, where the y-axis represents temperature 61 and the x-axis represents time 62. The schematic temperature curve 60 also shows the expected temperature 64, which can also be referred to as the normal temperature, and the measured temperature 66.

[0089] During the first step function 56, the controller 14 monitors the first step change 68 of the pin temperature. This could be the difference between the temperature during the baseline charging current 54 and the temperature increase caused by the first step function 56.

[0090] The temperature rise may be caused by Joule heating, which can be considered as the physical effect of an electric current generating heat energy as it passes through an electrical conductor. As those skilled in the art will recognize, defects or degradation in pin 32 may result in greater Joule heating than would be expected in pin 32 with virtually no such defects.

[0091] The controller 14 compares the first step change 68 of the pin temperature with the first expected temperature change 70 to produce a first deviation 72. This typically quantifies any excessive or unexpected heat generated by the pin 32 during the first step function 56.

[0092] The controller 14 can then compare the first deviation 72 with a predetermined threshold. If the first deviation 72 exceeds the predetermined threshold, the controller 14 can signal a maintenance alarm, and if the first deviation 72 is less than the predetermined threshold, the controller 14 can record or store the first deviation 72. In some cases, recording the first deviation 72 may include sending data from storage outside the vehicle 10 to the cloud or a network. The threshold may be specific to a certain type of vehicle 10 or may be a general threshold. Additionally, the threshold may be updated during the operational life of the vehicle 10, such as via a cloud network.

[0093] Depending on the magnitude of the first deviation 72, the maintenance alarm may include several possible actions or alerts. For example, but not limited to, the maintenance alarm may include warning the operator of vehicle 10 that vehicle 10 should be taken for maintenance, or in some cases, prematurely stopping the charging cycle to prevent further damage to the charging socket 30 or other parts of vehicle 10.

[0094] Factors that may cause degradation or damage to pin 32 may include, but are not limited to: external force bending pin 32, particle abrasion of the surface of pin 32, or unintentional exposure of charging socket 30 or pin 32 to heat. Factors that may cause further degradation of pin 32 during a charging cycle may include, but are not limited to: corrosion, surface cracks, arcing, or surface plating wear.

[0095] Identifying faults, degradations, or defects in pin 32 or other components of vehicle 10 can benefit vehicle 10, especially when early detection allows for the identification of minor faults before more significant problems arise. Benefits include, for example and but not limited to, preventing loss of propulsion or inability to charge vehicle 10 and RESS 12, thereby reducing traction and alternative transportation costs, and reducing labor costs associated with fault isolation or substantial damage to the systems of vehicle 10.

[0096] Note that, in addition to the first step function 56, the controller 14 may apply an additional step function during the charging cycle to further test the functionality of the charging socket 30. Therefore, the controller 14 may apply a second step function and compare the second step change in pin temperature with a second expected temperature change to generate a second deviation. Similarly, the controller may compare the second deviation with a predetermined threshold and determine whether a maintenance alarm signal is permitted and / or the temperature deviation is recorded.

[0097] In many cases, controller 14 will not attempt to test the functionality of charging socket 30 during each charging cycle. For example, but not limited to, the completion of the charging event can be delayed to analyze functionality using a step current or other testing mechanisms such as those described herein. Therefore, it may be beneficial to occasionally schedule / arrange this health assessment analysis, such as, for example, but not limited to, during extended charging cycles.

[0098] To determine during which charging cycles the system's functionality should be tested, controller 14 can use the history of vehicle 10 to better determine when extended charging cycles might occur. For example, but not limited to, scheduling methods can analyze GPS location and the history of previous charging cycles to determine extended charging periods when vehicle 10 is frequently at home (e.g., at night) or at a work location. Other factors may include, but are not limited to: time of day, ambient temperature, RESS 12 state of charge, requested battery power, time since the last health assessment, and the type of charging station connected to vehicle 10.

[0099] The scheduler method or function attempts to ensure uninterrupted charging when the operator wants to quickly gain some mileage without any delay (e.g., during fast charging during a trip), and plans for health monitoring of situations where the operator leaves vehicle 10 to charge for a longer period. Those skilled in the art will recognize the difference between short charging cycles and extended charging cycles. In one example, and not limited to, a predicted charging cycle lasting three hours or more can be considered an extended charging cycle; or an extended charging cycle is considered to occur when vehicle 10 remains connected to the charging station after RESS 12 is fully charged.

[0100] The first step function 56 and any subsequent step functions can be controlled by the scheduler. In some cases, the scheduler function can occur outside the vehicle, such as within a cloud network, and be transmitted to the controller 14. Note that even when the length of the charging cycle is estimated using the scheduler, the operator of the vehicle 10 may have irregular stops, allowing the controller 14 to suspend the health assessment of the charging system.

[0101] To perform a health assessment of the charging socket and its pins 32, the controller 14 uses various mechanisms to calculate the first expected temperature change 70. For example, but not limited to, the calculation may be based on a formula that equals the stored energy to the difference between the outflowing and inflowing energy plus the energy generated, which may include a physics-based thermal model.

[0102] Equation 1 shows a balanced, physics-based equation.

[0103] (1)

[0104] In equation 1: It is the transfer of heat and mechanical energy; It is the outflow of heat and mechanical energy transfer, such as through coolant circuit 20 or convective heat transfer to ambient air; It generates heat energy, such as through Joule heating; It is the stored heat energy that increases the temperature of pin 32.

[0105] Equation 2-5 includes a part of Equation 1.

[0106] (2)

[0107] (3)

[0108] (4)

[0109] (5)

[0110] In equation 2-5: R = resistance; I = current; H = convective heat transfer coefficient, where h amb It is for ambient air, and h f It refers to the fluid; T is the sensing temperature of socket pin 32; T amb It is the ambient air temperature; T f A1 is the surface area between the charging socket 30 and the ambient air; A2 is the surface area between the charging socket 30 and the coolant fluid; and ρVc is the heat capacity. By substituting Equations 2-5 into Equation 1, Equation 6 can be formed.

[0111] (6)

[0112] Rearrange equation 6 and use lumped parameters P1, P2, and P3 to form equation 7, where: P1 = ρVc; P2 = h amb * A1;P3 = H f *A2.

[0113] (7)

[0114] According to Equation 7, the controller 14 or its subsystem can determine the expected temperature 64 and calculate the first deviation 72 based on the difference between the first step change 68 and the first desired temperature change 70. Equation 7 can also be used to determine the effective resistance of one or more pins 32. Note that on-board calculations can be performed, for example, but not limited to, modeling functions or lookup tables.

[0115] Now for reference Figure 3 And referring to all other accompanying drawings, a schematic flowchart is shown illustrating a mechanism, method, or algorithm for testing and / or detecting the functionality of the charging socket 30. Method 100 in Figure 3 The document shows, and illustrates, one way to assess the health of the charging socket 30 and other parts of the vehicle 10 as described herein.

[0116] Step 110: Start / Initialize.

[0117] Method 100 can start operating when called by controller 14, can run continuously, or can loop repeatedly.

[0118] Step 112: Connect to the station and prepare to charge.

[0119] Method 100 determines whether vehicle 10 is connected to a charging station and whether it is ready to begin charging RESS 12. If these conditions are not met, the method returns to start step 110, which may include repeating or pausing until it resumes. Alternatively, start step 110 may be initialized only when vehicle 10 is connected to a charging station and ready to charge.

[0120] Step 114: Health Status Assessment Scheduler.

[0121] Method 100 communicates with the dispatcher, either on vehicle 10 or via a communication network. This helps determine whether vehicle 10 should be tested.

[0122] Step 116: Satisfy the enabling condition

[0123] If the conditions of the health assessment scheduler are not met, the method returns to the start step 110, which may include repeating or pausing until it starts again. If the conditions are met, method 100 proceeds to step 118.

[0124] Step 118: Monitor the temperature.

[0125] In this step, method 100 monitors a number of temperature conditions, including but not limited to: ambient air, coolant fluid, and charging socket 30, which may include one or more individual pins 32. These conditions form a baseline during the initial charging phase.

[0126] Step 120: Apply the step function and monitor the temperature.

[0127] After establishing the baseline, method 100 applies a step condition. Controller 14 can, for example, apply a first step function 56 to the charging current, such as... Figure 2A As shown in the diagram. Then, during and possibly after the first step function 56, method 100 monitors the changing temperature conditions in the charging socket 30, for example, by utilizing one or more thermocouples that effectively sense the charging socket 30.

[0128] Step 122: Determine the expected temperature and resistance.

[0129] Method 100 includes determining the expected temperature from a physics-based model, and also determining the resistance through one or more pins 32 or the entire charging socket 30. Method 100 uses the expected temperature and resistance in subsequent calculations and / or determinations.

[0130] Step 124: Estimate the deviation from the health socket.

[0131] Method 100 estimates the deviation from a healthy (i.e., normally operating) charging socket 30. Method 100 can determine the deviation using a comparison between the expected temperature and the measured temperature, such as... Figure 2B The first deviation 72 is shown in the figure. Alternatively, method 100 may compare the calculated resistance with the expected resistance based on current and voltage conditions from the charging station.

[0132] Step 126: Determine and report the health status of the socket / pin (optional).

[0133] Method 100 may include steps to determine the overall health status of the charging socket 30 or individual pins 32. This health status assessment may then be recorded or otherwise reported, such as to a cloud network. Determining the socket health status and reporting the health status determination can also be considered as overriding steps 124 and 132. In many cases, when the charging socket 30 is fully healthy, a summary report may be sent to the operator of the vehicle 10.

[0134] Step 128: Exceeding the predetermined threshold

[0135] Method 100 may compare the temperature deviation, resistance deviation, or both calculated in step 120 with a predetermined threshold. As those skilled in the art will recognize, these deviations may be vehicle-specific, for example, based on, but not limited to, the type and size of RESS12, the configuration of the charging socket 30, the drivetrain type, and other system configurations.

[0136] Step 130: Continue charging.

[0137] If the determination in step 128 is negative (i.e., the answer is no as indicated by the "-" in the flowchart), method 100 allows vehicle 10 to continue charging. In this case, method 100 may have determined that the charging cycle of the charging socket 30, RESS 12, or other components of vehicle 10 is generally harmless.

[0138] Step 132: Generate a fault message.

[0139] If the determination in step 128 is affirmative (i.e., the answer is yes as indicated by the "+" on the flowchart), method 100 generates a fault message. This may include, for example, but not limited to, signaling the vehicle operator via interior lights, a messaging system, or a portable device application; and / or, if vehicle 10 is part of a fleet, notifying the fleet manager.

[0140] Furthermore, depending on the severity of the deviation exceeding the threshold, step 132 may also include stopping the charging cycle. Particularly if optional step 126 determines that the health of the charging socket 30 has been significantly degraded, method 100 may determine that it is best to shut down the charging cycle without further delay. This may generate additional fault messages, including warnings to vehicle 10 and / or service or repair personnel at the charging station.

[0141] Step 134: End / Loop.

[0142] After step 130 or step 132, method 100 ends. In many configurations, method 100 will continuously cycle or cycle at regular intervals during the charging cycle.

[0143] Now for reference Figure 4 Referring to all other accompanying drawings, a charging socket 150 is shown, illustrating some possible damage to the charging socket as described herein. Those skilled in the art will recognize that the charging socket 150 is similar to... Figure 1 All or part of the charging socket 30 shown.

[0144] The charging socket 150 includes multiple pins 152, which are generally undamaged or in a working state. However, the charging socket 150 also includes damaged pins 153. The damaged pins 153 may have been broken by a charging cable that is not properly aligned with the charging socket 150. In addition, the damaged pins 153 may have caused an electric arc, resulting in the casing of the charging socket 150 surrounding the damaged pins 153 melting.

[0145] Additional methods for assessing the health status of charging sockets such as charging socket 150 or charging socket 30 may include image analysis of the respective charging socket. For example, but not limited to, the vehicle operator may be prompted to take photos or pictures of charging socket 150 at periodic intervals, or photos may be taken while the operator is tilted. The photos are then, for example, but not limited to, sent to a cloud network for image processing. The cloud network may utilize any number of technologies, including but not limited to manual inspection, image recognition, or artificial intelligence, to identify potential damage to charging socket 150.

[0146] If a cloud network or similar equipment system determines that there may be damage at the charging socket 150, it may signal or send a maintenance alert. Maintenance alerts may include, for example, but not limited to: signaling the vehicle operator via interior lights, a messaging system, or a portable device application; notifying the fleet manager if the vehicle 10 is part of a fleet; or alerting service or maintenance personnel.

[0147] Smartphones or personal device cameras can utilize apps or upload images for analysis over the internet. Detectable potential damage includes, but is not limited to, minor burn marks caused by electric arcs, grinding, cracks, or melting points.

[0148] like Figure 1 As shown, vehicle 10 includes a coolant circuit 20. In addition to performing a health assessment on the charging socket 30 itself, vehicle 10 can be configured to perform a health assessment on the coolant circuit 20. Figure 3 The flowchart represents a similar algorithm or method used to evaluate the coolant circuit 20.

[0149] The process of evaluating coolant circuit 20 includes similar steps. Figure 3 The method 100 shown monitors the temperature. However, in step 120, instead of applying a step to the charging current, the controller 14 maintains a stable charging current while applying a step to the liquid coolant flow through the coolant circuit 20, and monitors the temperature change during the coolant step.

[0150] A coolant step can be applied to increase or decrease the flow. For example, if the coolant flow through coolant circuit 20 is increased, the temperature of pin 32 in charging socket 30 is expected to decrease. However, if coolant circuit 20 is not operating properly, the temperature reduction may not be fully achieved.

[0151] The deviation can be calculated from the difference between the measured temperature and the expected temperature at pin 32. Controller 14 can be connected to... Figure 3 The method shown is similar to comparing this deviation with a threshold to assess the health of the coolant circuit 20.

[0152] like Figure 1 As shown, the charging socket 30 includes a lock 40 that interacts with a corresponding locking mechanism on the charging cable. However, the lock 40 of the charging cable lock may become damaged or malfunction. Therefore, it may be beneficial to conduct a health assessment of the lock 40 and / or the charging cable lock.

[0153] In many interactions, lock 40 and the charging cable lock must successfully lock each other before a charging cycle can begin or be initiated. Therefore, controller 14 knows whether lock 40 and the charging cable lock have successfully engaged. Thus, a health assessment can be performed on lock 40, the corresponding charging cable lock, or both.

[0154] For example, but not limited to, if lock 40 typically locks successfully on the first or second attempt, but requires five attempts to lock at a particular charging station, this indicates that the charging cable lock may be damaged or otherwise malfunctioning. Controller 14 can then use the communication network to signal to the charging station that inspection and / or repair may be necessary. Similarly, but not limited to, if lock 40 has difficulty locking successfully at a charging station that typically locks on the first or second attempt, controller 14 may determine that lock 40 is not functioning correctly and send a maintenance message or reminder to inspect and / or repair lock 40.

[0155] The detailed descriptions and accompanying drawings or figures are supportive and descriptive of the subject matter herein. While some best practices and other embodiments have been described in detail, various alternative designs, embodiments, and configurations exist.

[0156] Furthermore, features of any embodiments shown in the accompanying drawings or various embodiments mentioned in this specification are not necessarily to be construed as independent embodiments. Rather, each feature described in one example of an embodiment may be combined with one or more other desired features from other embodiments to obtain other embodiments not described in words or by reference to the accompanying drawings. Therefore, these other embodiments fall within the scope of the appended claims.

Claims

1. A method for detecting the functionality of multiple pins in a vehicle's charging socket during a charging cycle, comprising: The charging current is provided through the pin; The pin temperature is monitored by the controller during the charging current. The controller applies a first step function to the charging current; During the first step function, monitor the first step change in the pin temperature; The first step change in the pin temperature is compared with a first expected temperature change to generate a first deviation; and the first deviation is compared with a predetermined threshold: If the first deviation exceeds the predetermined threshold, a maintenance alarm signal is issued; if the first deviation is less than the predetermined threshold, the first deviation is recorded. The first step function is scheduled so that it does not occur during each charging cycle, and the first step function is scheduled based on vehicle history so that the detection of the pin's function occurs during extended charging cycles.

2. The method according to claim 1, further comprising: The controller applies a second step function to the charging current; During the second step function, monitor the second step change in the pin temperature; The second step change in the pin temperature is compared with a second expected temperature change to generate a second deviation; and the second deviation is compared with the predetermined threshold: If the second deviation exceeds the predetermined threshold, a maintenance alarm signal is issued; if the second deviation is less than the predetermined threshold, the second deviation is recorded.

3. The method according to claim 1, further comprising: The first expected temperature change is calculated based on a formula that equals the difference between the outflow and inflow energy plus the energy generated.

4. The method according to claim 3, further comprising: The first expected temperature change is calculated based on a physics-based thermal model.

5. The method according to claim 2, further comprising: The first and second step functions are scheduled based on vehicle history. The first step function and the second step function do not occur during each charging cycle, and the function detection of the pin occurs during extended charging cycles.

6. A vehicle comprising: A rechargeable energy storage system that selectively undergoes charging cycles; A charging socket with multiple pins; A controller, which communicates with the rechargeable energy storage system and the charging socket, is configured to detect the functionality of the charging socket during the charging cycle by: The charging current is provided through the pin; The pin temperature of the pin is monitored during the charging current. Apply the first step function to the charging current; During the first step function, monitor the first step change in the pin temperature; The first step change in the pin temperature is compared with a first expected temperature change to generate a first deviation; and the first deviation is compared with a predetermined threshold: If the first deviation exceeds the predetermined threshold, a maintenance alarm signal is issued; if the first deviation is less than the predetermined threshold, the first deviation is recorded. The controller is further configured to detect the functionality of the charging socket during the charging cycle by: Schedule the first step function so that it does not occur during each charging cycle; The controller is further configured to detect the functionality of the charging socket during the charging cycle by: The first step function is scheduled based on vehicle history, so that the function of the pin is detected during the extended charging cycle.

7. The vehicle according to claim 6, wherein, The controller is also configured to detect the functionality of the charging socket during the charging cycle by: The second step function is applied to the charging current; During the second step function, monitor the second step change in the pin temperature; The second step change in the pin temperature is compared with a second expected temperature change to generate a second deviation; and the second deviation is compared with the predetermined threshold: If the second deviation exceeds the predetermined threshold, a maintenance alarm signal is issued; if the second deviation is less than the predetermined threshold, the second deviation is recorded.

8. The vehicle according to claim 6, wherein, The controller is also configured to detect the functionality of the charging socket during the charging cycle by: The first expected temperature change is calculated based on a formula that equals the difference between the outflow and inflow energy plus the energy generated.

9. The vehicle according to claim 8, wherein, The controller is also configured to detect the functionality of the charging socket during the charging cycle by: The first expected temperature change is calculated based on a physics-based thermal model.

10. The vehicle according to claim 7, wherein, The controller is also configured to detect the functionality of the charging socket during the charging cycle by: The first and second step functions are scheduled based on vehicle history. The first step function and the second step function do not occur during each charging cycle, and the function of detecting the pin is included during extended charging cycles.

11. The vehicle according to claim 6, further comprising: The lock on the charging socket prevents the initiation of the charging cycle unless it is successfully locked to the corresponding structure.

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