Electric vehicle electrical wiring assembly, system and method for identifying faults in an electric vehicle electrical wiring assembly

Abstract

Disclosed is an electric vehicle electrical wiring assembly fault status human interface. The disclosure relates to an electric vehicle electrical wiring assembly and a system for identifying a fault in an electric vehicle electrical wiring assembly. The electric vehicle electrical wiring assembly and system includes an electrical wiring assembly controller. The electrical wiring assembly controller includes an electrical wiring assembly processor, a plurality of fault detection circuits connected to the electrical wiring assembly processor, and a first status light connected to the electrical wiring assembly processor. The electrical wiring assembly processor is configured to execute a set of instructions including identifying a fault in one of the fault detection circuits, terminating power in the electrical wiring assembly, turning on the first status light indicating that a fault is present, and encoding the fault in the first status light by modulating the first status light.

Description

Technical Field

[0001] This disclosure relates to an electric vehicle cordset and a system and method for identifying faults in the electric vehicle cordset. Background Technology

[0002] Electric vehicles are charged using wiring assemblies that connect the vehicle to a home electrical wiring system or a charging station power source. For home-based charging systems, some wiring assemblies plug into a standard 120V or 240V outlet, while others connect directly to the wiring system. The wiring assemblies include a human-machine interface (HMI) that includes lights indicating the charging status of the wiring assembly. These indicators include status signals for charging and status signals for identifying faults, as well as status signals coded by modulation to identify specific faults when they are detected. In one example, the wiring assembly emits green light to indicate that it is charging, while a fault in charging capability is indicated by amber light.

[0003] Wiring assemblies can indicate the presence of specific faults by illuminating various combinations of lights. However, the number of available light combinations is limited by the number of lights supplied, and it may not be possible to specifically identify many possible faults or their locations. Furthermore, relying on the user to interpret the various light combinations can lead to misidentification of faults.

[0004] Therefore, while current wiring assembly fault condition indications for electric vehicles have achieved their intended purpose, a new and improved system and process are needed to provide wiring assembly fault condition indications. Summary of the Invention

[0005] According to several aspects, this disclosure relates to an electric vehicle wiring assembly. The electric vehicle wiring assembly includes a wiring assembly controller. The wiring assembly controller includes: a wiring assembly processor; a plurality of fault detection circuits connected to the wiring assembly processor; and a first status light connected to the wiring assembly processor. The wiring assembly processor is configured to: identify a fault in one of the plurality of fault detection circuits, terminate power to the wiring assembly, turn on the first status light indicating the presence of a fault, and encode the fault in the first status light by modulating the first status light.

[0006] Of all the above aspects, the fault is coded by changing the duty cycle of the first state light.

[0007] In all of the above aspects, the electric vehicle wiring assembly further includes a wiring assembly cable, which includes a vehicle adapter at a first end of the wiring assembly cable and a wiring system adapter at a second end of the wiring assembly cable, wherein a wiring assembly controller is connected to the wiring assembly cable.

[0008] In the above aspects, the plurality of fault detection circuits include one or more of the following: a power plug overheat detection circuit, a ground fault detection circuit, a power plug ground loss detection circuit, and a controller internal failure detection circuit.

[0009] In all of the above aspects, the wire assembly processor is further configured to: cut off the second status light indicating that the wire assembly is charging.

[0010] In a further aspect, the second state light is green, and the first state light is amber.

[0011] According to a further aspect, this disclosure relates to a system for identifying faults in wiring assemblies of an electric vehicle. The system includes a wiring assembly controller. The wiring assembly controller includes: a wiring assembly processor; a plurality of fault detection circuits connected to the wiring assembly processor; and a first status light connected to the wiring assembly processor, wherein the wiring assembly processor is configured to: identify a fault in one of the fault detection circuits, terminate power to the wiring assembly, turn on the first status light indicating the presence of a fault, and encode the fault in the first status light by modulating the first status light. The system further includes an electric vehicle. The electric vehicle includes: a first vision processing module; a first light sensor connected to the first vision processing module; and a first display connected to the first vision processing module. The first light sensor is configured to detect light emitted by the first status light, the first vision processing module is configured to decode the fault encoded in the modulated first status light, and the first display is configured to display the fault decoded by the first vision processing module.

[0012] Of all the above aspects, the fault is coded by changing the duty cycle of the first state light.

[0013] In the above aspects, the plurality of fault detection circuits include one or more of the following: a power plug overheat detection circuit, a ground fault detection circuit, a power plug ground loss detection circuit, and a controller internal failure detection circuit.

[0014] In a further aspect above, the wire assembly controller is further configured to: cut off a second status light indicating that the wire assembly is charging.

[0015] In a further aspect above, the system also includes a communication system configured to transfer faults to an external entity.

[0016] In any of the above aspects, the system further includes an external diagnostic visualization device.

[0017] In all the above aspects, the external diagnostic visualization device includes: an external vision processing module; an external light sensor connected to the external vision processing module; and an external display connected to the external vision processing module. The external light sensor is configured to detect light emitted by a first status light, the external vision processing module is configured to decode faults encoded in the modulated first status light, and the external display is configured to display the faults decoded by the external vision processing module.

[0018] Among the above aspects, the external diagnostic visualization device also includes an external communication system configured to transfer faults to external entities.

[0019] In any of the above aspects, the external diagnostic visualization device is a smartphone. Alternatively, in any of the above aspects, the external diagnostic visualization device is a diagnostic unit.

[0020] According to an additional aspect, this disclosure relates to a method for identifying a fault in a wiring assembly of an electric vehicle. The method includes: identifying a fault in the wiring assembly using a fault detection circuit included in a wiring assembly controller; terminating power to the wiring assembly; indicating the presence of a fault using a first status light in the wiring assembly controller; and encoding the fault in the first status light by modulating the first status light using a wiring assembly processor included in the wiring assembly controller.

[0021] In all of the above aspects, the method further includes: using a first light sensor to detect light emitted by a first status light, using a first vision processing module to decode a fault encoded in the first status light, and using a first display to display the fault decoded by the first vision processing module.

[0022] In all of the above aspects, the method further includes: using a first communication system to transfer the fault to an external entity.

[0023] In all of the above aspects, the method further includes: using an external light sensor to detect light emitted by a first status light, using an external vision processing module to decode a fault encoded in the first status light, and using an external display to display the fault decoded by the external vision processing module.

[0024] The present invention also discloses the following technical solutions:

[0025] Option 1. An electric vehicle wiring assembly, comprising:

[0026] Wire assembly controller, the wire assembly controller comprising:

[0027] Wire assembly processor,

[0028] Multiple fault detection circuits are connected to the wire assembly processor, and

[0029] A first status light, which is connected to the wiring assembly processor.

[0030] The wire assembly processor is configured as follows:

[0031] A fault is identified in at least one of the plurality of fault detection circuits.

[0032] Terminate the power supply to the wire assembly.

[0033] Turn on the first status light indicating the presence of the fault, and

[0034] The fault is encoded in the first status light by modulating the first status light.

[0035] Option 2. The electric vehicle wiring assembly according to Option 1, wherein the fault is encoded by changing the duty cycle of the first status light.

[0036] Option 3. The electric vehicle wiring assembly according to Option 1, further comprising a wiring assembly cable, the wiring assembly cable including a vehicle adapter at a first end of the wiring assembly cable and a wiring system adapter at a second end of the wiring assembly cable, wherein the wiring assembly controller is connected to the wiring assembly cable.

[0037] Option 4. The electric vehicle wiring assembly according to Option 1, wherein the plurality of fault detection circuits includes one or more of the following: an overheat detection circuit for the power grid plug, a ground fault detection circuit, a ground loss detection circuit for the power grid plug, and an internal failure detection circuit for the controller.

[0038] Option 5. The electric vehicle wiring assembly according to Option 1, wherein the wiring assembly processor is further configured to: cut off a second status light indicating that the wiring assembly is charging.

[0039] Option 6. The electric vehicle wiring assembly according to Option 5, wherein the second status light is green and the first status light is amber.

[0040] Option 7. A system for identifying faults in wiring assemblies of electric vehicles, the system comprising:

[0041] Wire assembly controller, the wire assembly controller comprising:

[0042] Wire assembly processor,

[0043] Multiple fault detection circuits are connected to the wire assembly processor, and

[0044] A first status light, which is connected to the wiring assembly processor.

[0045] The wire assembly processor is configured to: identify a fault in at least one of the plurality of fault detection circuits, terminate power to the wire assembly, turn on a first status light indicating the presence of the fault, and encode the fault in the first status light by modulating the first status light; and

[0046] Electric vehicles, the electric vehicles including:

[0047] First vision processing module,

[0048] A first light sensor, which is connected to the first vision processing module, and

[0049] A first display is connected to the first visual processing module.

[0050] The first light sensor is configured to detect light emitted by the first status light, the first vision processing module is configured to decode the fault encoded in the modulated first status light, and the first display is configured to display the fault decoded by the first vision processing module.

[0051] Option 8. The system for identifying faults in the wiring assembly of an electric vehicle according to Option 7, wherein the fault is encoded by changing the duty cycle of the first status light.

[0052] Option 9. The system for identifying faults in the wiring assembly of an electric vehicle according to Option 7, wherein the plurality of fault detection circuits includes one or more of the following: a mains plug overheat detection circuit, a ground fault detection circuit, a mains plug ground loss detection circuit, and a controller internal failure detection circuit.

[0053] Option 10. The system for identifying faults in the wiring assembly of an electric vehicle according to Option 7, wherein the wiring assembly processor is further configured to: cut off a second status light indicating that the wiring assembly is charging.

[0054] Option 11. The system for identifying faults in the wiring assembly of an electric vehicle according to Option 7, further comprising a communication system configured to transfer the fault to an external entity.

[0055] Option 12. The system for identifying faults in the wiring assemblies of electric vehicles according to Option 7, further comprising an external diagnostic visualization device.

[0056] Option 13. The system for identifying faults in wiring assemblies of electric vehicles according to Option 12, wherein the external diagnostic visualization device comprises:

[0057] External vision processing module,

[0058] An external light sensor, which is connected to the external vision processing module, and

[0059] An external display, which is connected to the external vision processing module,

[0060] The external light sensor is configured to detect light emitted by the first status light, the external vision processing module is configured to decode the fault encoded in the modulated first status light, and the external display is configured to display the fault decoded by the external vision processing module.

[0061] Option 14. The system for identifying faults in wiring assemblies of electric vehicles according to Option 12, wherein the external diagnostic visualization device includes an external communication system configured to transfer the fault to an external entity.

[0062] Option 15. The system for identifying faults in the wiring assembly of an electric vehicle according to Option 12, wherein the external diagnostic visualization device is a smartphone.

[0063] Option 16. The system for identifying faults in the wiring assembly of an electric vehicle according to Option 12, wherein the external diagnostic visualization device is a diagnostic unit.

[0064] Solution 17. A method for identifying faults in wiring assemblies of electric vehicles, the method comprising:

[0065] Faults in the wire assembly are identified by using fault detection circuitry included in the wire assembly controller.

[0066] Terminate the power supply to the wire assembly;

[0067] The fault is indicated by a first status light in the wiring assembly controller; and

[0068] The fault is encoded in the first status light by modulating the first status light using a wire assembly processor included in the wire assembly controller.

[0069] Solution 18. The method according to Solution 17, further comprising: using a first light sensor to detect light emitted by the first status light, using a first vision processing module to decode the fault encoded in the first status light, and using a first display to display the fault decoded by the first vision processing module.

[0070] Option 19. The method according to Option 18 further includes: using a first communication system to transfer the fault to an external entity.

[0071] Option 20. The method according to Option 17, further comprising: using an external light sensor to detect light emitted by the first status light, using an external vision processing module to decode the fault encoded in the first status light, and using an external display to display the fault decoded by the external vision processing module. Attached Figure Description

[0072] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.

[0073] Figure 1 The illustration shows an electric vehicle according to various aspects of this disclosure, a wiring assembly for charging the electric vehicle, and an external diagnostic visualization device.

[0074] Figure 2 The illustration shows a schematic diagram of a vision processing module with associated sensors and display units present in an electric vehicle according to various aspects of the present disclosure;

[0075] Figure 3 The illustration shows a schematic diagram of an embodiment of a wire assembly controller according to various aspects of the present disclosure;

[0076] Figure 4 The illustration shows a schematic diagram of an external diagnostic visualization instrument according to various aspects of this disclosure;

[0077] Figure 5 The illustration shows a method for encoding faults in a wire assembly controller according to various aspects of this disclosure;

[0078] Figure 6 The illustration shows a method for decoding a fault transmitted by a wiring harness controller in an electric vehicle, according to various aspects of this disclosure.

[0079] Figure 7 The illustration depicts a method for decoding faults communicated by a wire assembly controller using an external diagnostic visualization instrument, according to various aspects of this disclosure; and

[0080] Figure 8The illustration depicts a method for reporting fault data conveyed by a wiring harness controller by an electric vehicle or external diagnostic visualization device, according to various aspects of this disclosure. Detailed Implementation

[0081] This disclosure relates to a system and process for indicatively displaying to a user the functional status of an electric vehicle charging cable assembly via a human-machine interface for electric vehicle cable assembly fault status. The status of the cable assembly is encoded in a first status light by modulating light emitted from the first status light through a change in duty cycle, to optically transmit the encoded light signal to a light sensor present in the vehicle or an external diagnostic visualizer. A vision processing module then decodes the status of the cable assembly and conveys it to the user via a display associated with the vehicle or external diagnostic visualizer to identify the nature of any fault and the location of any fault (e.g., in the electric vehicle, the cable assembly, or the power supply). The light signal may also provide the user with an initial visual indication of the general status of the charger, including whether the charger is providing charging or whether a fault exists.

[0082] Figures 1 to 4 The illustration shows aspects of a system for indicating the functional state of an electric vehicle charging cable assembly. The system includes an electric vehicle 100 and a cable assembly 104 for coupling the electric vehicle 100 to a power source 12. The electric vehicle 100 includes, for example, a fully electric vehicle or a plug-in hybrid electric vehicle. Although a hatchback is illustrated, the electric vehicle 100 can include any electric vehicle, such as a sedan, truck, hatchback, all-terrain vehicle, motorcycle, etc. The electric vehicle 100 includes a battery 14 to supply power to a powertrain 16, and other systems within the electric vehicle 100. Additionally, the electric vehicle 100 includes a first light sensor 18, a first electronic control unit 22, and a first display 20.

[0083] The first light sensor 18 can be positioned anywhere on the electric vehicle 100, provided that it is in a position where it can detect the light L emitted from the wiring assembly 104. For example... Figure 1 As shown, the first light sensor 18 is positioned at the front of the electric vehicle 100. Alternatively or additionally, the first light sensor 18 may be positioned on either side of the vehicle or at the rear of the vehicle, or in various aspects within the compartment 102. The first light sensor 18 may be, for example, a light sensor, a complementary metal-oxide-semiconductor (CMOS) device, and a charge-coupled device. In various aspects, the first light sensor 18 is configured to detect light emitted from the wiring assembly 104 at wavelengths and frequencies that may be within the visible light range or may be infrared or ultraviolet light outside the visible spectrum.

[0084] like Figure 2As illustrated, a first light sensor 18 is connected to a first vision processing module 24 in an electronic control unit 22. The electronic control unit 22 regulates the power delivered to and from the battery 14 to the powertrain 16 and various other subsystems of the electric vehicle 100. The vision processing module 24 in the electronic control unit 22 may include a custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor among several processors associated with the first vision processing module 24, a semiconductor-based microprocessor (in the form of a microchip or chipset), a combination of microprocessors, or generally means for executing instructions. In various aspects, there may be more than one vision processing module 24, wherein processing may be distributed across multiple vision processing modules 24.

[0085] Additionally, further reference Figure 2 The electric vehicle 100 includes a first display 20. The first display 20 is located in the compartment 102 of the electric vehicle 100 (see...). Figure 1 Furthermore, the first display 20 is visually accessible to a user within the electric vehicle 100. The first display 20 includes a graphical user interface 106, which the user can interact with using, for example, a touchscreen integrated into the graphical user interface 106 or an electromechanical interface located elsewhere in the cabin 102. The first display 20 is configured to indicate the fault status of the wiring assembly 104 to the user in the event of a malfunction.

[0086] Refer again Figure 1 The electric vehicle 100 may also include a first communication system 30 configured to wirelessly transmit information from the electronic control unit 22 to an external entity 32, such as, but not limited to, other vehicles (“V2V” communication), infrastructure (“V2I” communication), remote systems at remote call centers (e.g., General Motors’ ON-STAR), and / or personal devices (e.g., external diagnostic visualization 150). In some embodiments, the first communication system 30 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using the IEEE 802.11 standard or by using cellular data communication. However, additional or alternative communication methods, such as dedicated short-range communication (DSRC) channels, are also contemplated within the scope of this disclosure. A DSRC channel refers to a one-way or two-way short- to medium-range wireless communication channel designed specifically for automotive applications, along with a corresponding set of protocols and standards. Therefore, the first communication system 30 may include one or more antennas and / or transceivers for receiving and / or transmitting signals, such as cooperative sensing messages (CSM).

[0087] In various aspects, power source 12 is a home or building wiring system. In alternative aspects, power source 12 is a stand-alone charging station. And in yet another aspect, power source 12 is a generator or battery. As implied above, wiring assembly 104 includes wiring assembly cable 105 comprising multiple wires connecting electric vehicle 100 to power source 12. Wiring assembly 104 includes a vehicle adapter 120 at one end 108 connecting wiring assembly 104 to vehicle 100, and a wiring system adapter 122 at the other end 110 connecting wiring assembly 104 to power source 12. In various aspects, wiring system adapter 122 includes a 120 V or 240 V plug, and power source 12 includes a socket 124 for receiving 120 V or 240 V from wiring system adapter 122. Wiring assembly 104 also includes wiring assembly controller 126 that monitors the status of wiring assembly 104 and provides indications of charging status, as further described herein.

[0088] Figure 3 A block diagram of a wire assembly controller 126 is shown. The wire assembly controller 126 includes a wire assembly processor 130 and one or more status lights. Additionally, the wire assembly controller 126 includes several circuits for fault detection, including but not limited to one or more of the following: a mains plug overheat detection circuit 134, a ground fault detection circuit 136, a mains plug ground loss detection circuit 138, and a controller internal failure detection circuit 140. Further, the wire assembly controller 126 includes a non-transitory computer-readable storage device 142.

[0089] The wire assembly processor 130 may be a custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor among several processors associated with the wire assembly controller 126, a semiconductor-based microprocessor (in the form of a microchip or chipset), a combination of microprocessors, or a generally used means for executing instructions. In various aspects, the wire assembly processor 130 includes display driver circuitry for driving the status lamp 132. In various aspects, there may be more than one wire assembly processor 130, wherein processing is distributed across multiple wire assembly processors 130, as in the case of parallel processing. The wire assembly controller 126 is programmed to execute instructions for conveying fault states detected by the wire assembly processor 130, as described in detail below.

[0090] Status light 132 provides a first human-machine interface and a first machine-machine interface. In various aspects, status light 132 includes two lights 132a and 132b; however, alternatively, one light may be present, or more than two lights may be present, such as three to four lights. Status light 132 includes: a first status light 132a for indicating one or more faults in the wiring assembly 104; and a second status light 132b for indicating that the wiring assembly 104 is charging or preparing to charge, and may also be used in conjunction with the first status light 132a to indicate one or more faults in the wiring assembly 104. The first status light may be, for example, an amber status light, and the second status light may be, for example, a green status light. Status light 132 is a light-emitting diode (LED) or other light that can be modulated by controlling the change of its duty cycle. Status light 132 emits light L, which is detected by, for example, a light sensor 18 associated with the electric vehicle 100 and any other external light sensor 154 capable of detecting the light L emitted by status light 132. The light L emitted by the status light 132 is modulated by the wiring assembly processor 130 in a manner detectable by either the light sensor 18 associated with the electric vehicle 100 or the external light sensor 154 associated with the external diagnostic visualization device 150. However, a user observing the light L may not be able to discern the modulation of the light L. Although the status light 132... Figure 1 The status light 132 is illustrated as a discrete circular light, but it should be understood that the status light 132 can be of any shape. For example, the status light 132 can be provided as a strip surrounding the wire assembly controller 126, which is capable of emitting light in any direction around the wire assembly controller 126, so that the observation of the modulated light L is not limited to a single surface of the wire assembly controller 126.

[0091] The mains plug overheat detection circuit 134 monitors the temperature of the connection between the wiring assembly 104 and the power supply 12. The mains plug overheat detection circuit 134 includes a temperature sensing device 144 (such as a thermistor or thermocouple) for detecting temperature changes (especially increases) in the wiring system adapter 122. Alternatively, the temperature sensing device 144 is provided in the power supply 12 (e.g., in the socket 124), which then communicates the temperature status in the socket 124 via the wiring assembly controller 126. Communication between the power supply 12 and the wiring assembly processor 130 can occur via power line communication, a secondary communication cable provided in the wiring assembly 104, or via wireless communication using wireless communication protocols (such as 802.11, Bluetooth®, etc.). If the detected temperature change is outside the temperature range required for operating the wiring assembly 104 and charging the electric vehicle 100, the mains plug overheat detection circuit 134 will terminate power from the wiring assembly 104 to the electric vehicle 100.

[0092] The ground fault detection circuit 136 includes a current monitoring sensor 146 that detects a mismatch in the amount of current flowing between the hot wire and the neutral wire of the wiring assembly 104. When a mismatch greater than a few milliamps is detected, the ground fault detection circuit 136 cuts off power to the wiring assembly 104. The wiring assembly 104 may include a battery or backup power supply 148 connected to the wiring assembly controller 126 in the event of power termination to the wiring assembly 104, allowing the wiring assembly controller 126 to indicate the status of the wiring assembly 104. If the ground fault detection circuit 136 detects a current mismatch between the hot wire and the neutral wire of the wiring assembly 104 greater than a given setpoint, the ground fault detection circuit 136 will terminate power from the wiring assembly 104 to the electric vehicle 100.

[0093] The grounding loss detection circuit 138 monitors for faulty grounding connections in the electrical system of the electric vehicle 100 between the vehicle battery / chassis ground and the electronic control unit within the vehicle. This grounding loss detection circuit 138 may be located in the vehicle adapter 120 or in the vehicle's own electronic control unit 22. If located within the electric vehicle 100, communication between the electric vehicle 100 and the wiring assembly processor 130 may occur via power line communication, a secondary communication cable provided in the wiring assembly 104, or via wireless communication using wireless communication protocols (such as 802.11, Bluetooth®, etc.). If the grounding loss detection circuit 138 detects a grounding loss at the grounding plug, it will terminate power from the wiring assembly 104 to the electric vehicle 100, even if it is only a partial loss.

[0094] The controller's internal failure detection circuit 140 monitors the circuitry within the wiring assembly 104. The controller's internal failure detection circuit 140 performs various functions, including monitoring the oscillator's consistency and checking logs to ensure that the methods embodied by the coded instructions are being executed error-free. If an internal failure is detected in the wiring assembly controller 126, the controller's internal failure detection circuit 140 will terminate power from the wiring assembly 104 to the electric vehicle 100.

[0095] For example, the computer-readable storage device or medium 142 may include volatile and non-volatile storage devices such as read-only memory (ROM), random access memory (RAM), and non-fail-to-reset memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operational variables when the wire assembly processor 130 is powered off. The computer-readable storage device or medium 142 may be implemented using several memory devices, such as PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or other electrical, magnetic, optical, or combined memory devices capable of storing data, some of which represent executable instructions used by the wire assembly processor 130. In various aspects, the storage device 142 includes a lookup table that provides instructions to encode at least the first status lamp 132 for a specific fault identified by logic in the wire assembly processor 130.

[0096] In addition, in all the above aspects, the external diagnostic visualization device 150 is associated with the wiring assembly 104, such as... Figure 1 and 4 As illustrated in the figure. An external diagnostic visualization device 150 may include, for example, a smartphone associated with a user, or a diagnostic unit that may be located in a repair shop. The external diagnostic visualization device 150 includes an external vision processing module 152. The external vision processing module 152 may include a custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), an auxiliary processor among several processors associated with the external vision processing module 152, a semiconductor-based microprocessor (in the form of a microchip or chipset), a combination of microprocessors, or a generally used means for executing instructions. In all aspects, there may be more than one external vision processing module 152, wherein processing is distributed across multiple external vision processing modules 152, as in the case of parallel processing. The external diagnostic visualization device 150 may include an application (i.e., a software program or a set of instructions) for decoding modulated light L emitted from the wiring assembly controller 126. This application may also include instructions for: identifying the electric vehicle 100 and displaying faults to the user, and identifying the location of the electric vehicle 100, the wiring assembly 104, and the environmental conditions in which the electric vehicle 100 is located. The application may be stored in computer-readable storage device 142, or in an additional or separate memory.

[0097] The external diagnostic visualization device 150 also includes an external light sensor 154, such as a light sensor, complementary metal-oxide-semiconductor, and charge-coupled device, connected to the external vision processing module 152. The external light sensor 154 detects light emitted from the wire assembly 104. That is, the external light sensor 154 is configured to detect light L emitted from the wire assembly 104 at a wavelength and frequency. As described above, such wavelengths may include those in the visible spectrum and, alternatively, those in the infrared or ultraviolet spectrum. Figure 4 As illustrated, an external light sensor 154 is connected to an external vision processing module 152. In the case of an external diagnostic visual device 150 that is a smartphone, the external light sensor...

[0098] The external diagnostic visualization device 150 further includes an external display 156 connected to the external vision processing module 152, such as... Figure 4 As illustrated in the figure, an external display 156 can be visually accessed by a user outside or inside the electric vehicle 100. The external display 156 includes a graphical user interface 158, which the user can interact with using, for example, a touchscreen integrated into the graphical user interface 158 or an electromechanical interface connected to the external diagnostic visualization 150. The external diagnostic visualization 150 may also include an external communication system 160 configured to wirelessly transmit information from an external video processing module 152 to an external entity 32, such as, but not limited to, other vehicles (“V2V” communication), infrastructure (“V2I” communication), and / or a remote system at a remote call center (e.g., General Motors’ ON-STAR). In some embodiments, the external communication system 160 is a wireless communication system configured to communicate via a wireless local area network (WLAN) using the IEEE 802.11 standard or by using cellular data communication. However, additional or alternative communication methods, such as dedicated short-range communication (DSRC) channels, are also contemplated within the scope of this disclosure. DSRC channels refer to one-way or two-way short-to-medium-range wireless communication channels designed specifically for automotive applications, along with a set of corresponding protocols and standards. Therefore, external communication system 160 may include one or more antennas and / or transceivers for receiving and / or transmitting signals such as Cooperative Sensing Messages (CSM).

[0099] The wire assembly processor 130 is configured to execute diagnostic instructions. These diagnostic instructions may include one or more separate programs, each comprising an ordered list of executable instructions for implementing logical functions. When executed by the wire assembly processor 130, the diagnostic instructions receive and process signals from various circuits present in the wire assembly controller 126; perform logic, calculations, methods, and / or algorithms to drive the status lights 132; and, depending on a fault detected by the wire assembly controller 126 (if any), modify the modulation of the light emitted by at least the first status light 132 and, in some respects, the second status light to provide coded signals.

[0100] In a non-limiting example, if no fault exists, the second status light 132 illuminates while the first status light remains off. If a ground fault failure is detected, the first status light 132 can be encoded with a 60% duty cycle, meaning it is illuminated for 60% of a given time period. For a mains plug overheating failure, the encoded optical signal emitted by the first status light 132 can be encoded with a 70% duty cycle, meaning one or more of the status lights 132 are illuminated for 70% of a given time period. For a mains plug grounding loss, the encoded optical signal emitted by the first status light 132 can be encoded with an 80% duty cycle, meaning one or more of the status lights 132 are illuminated for 80% of a given time period. And for an internal controller failure, the encoded optical signal emitted by the first status light 132 can be encoded with a 90% duty cycle, meaning one or more of the status lights 132 are illuminated for 90% of a given time period. Therefore, it should be understood that the duty cycle of the lamp can be set in the range of 10% to 100%, where the duty cycle is understood as the percentage of time the status lamp is on during a given time period. In all respects, the time period for calibrating the duty cycle is determined by the frame rate of the light sensors 18 and 154. Thus, in the example above, if the light sensors 18 and 154 use a frame rate of 30 frames per second, then for a 60% duty cycle, the status lamp 132 will be on for 18 of the 30 frames and off for 12 of the 30 frames, where the on and off periods can be consecutive or alternating. The duty cycle can be adjusted to accommodate light sensors 18 and 154 operating at 30 frames per second; or alternatively, greater than 30 frames per second (e.g., in the range of 31 to 60 frames per second), or less than 30 frames per second (e.g., in the range of 20 to 29 frames per second). Therefore, by adjusting the duty cycle of the status lamp 132 and modulating the status lamp 132 accordingly, a large number of fault indications can be encoded.

[0101] Therefore, the diagnostic instructions implement a method for identifying, encoding, and displaying faults by the wire assembly controller 126, aspects of which are... Figure 5The method 200 begins at block 202, where the wiring assembly 104 is connected to the electric vehicle 100 for charging. A second status light 132 on the wiring assembly controller 126 indicates that the wiring assembly 104 is charging and that the wiring assembly controller 126 is monitoring for a fault in the wiring assembly 104. At block 204, a fault is identified in one of the fault detection circuits by the wiring assembly processor 130, and either the fault is triggered by the circuit in the wiring assembly controller 126 or the wiring assembly controller 126 terminates the power supply from the wiring assembly 104 to the electric vehicle 100. At block 206, the wiring assembly controller 126 turns off the status light 132 indicating that the wiring assembly 104 is charging or ready to charge. At block 208, the wiring assembly controller 126 turns on the first status light 132 to indicate a fault in the wiring assembly 104 if a fault has been identified, and at block 210, the wiring assembly controller 126 encodes the type of fault and modulates the light emitted by the first status light 132 accordingly. At block 212, the agreement is terminated until the fault in wire assembly 104 is resolved.

[0102] Then, the light L emitted by the status light 132 is detected by a light sensor, such as a light sensor 18 present in the electric vehicle 100, or an external light sensor 154 associated with an external diagnostic visualization 150 (such as a smartphone). The external diagnostic visualization 150 is configured to execute decoding instructions to detect and interpret the light emitted by the status light 132 of the wiring assembly controller 126 and display information about the emitted decoded light in a user-understandable manner. The decoding instructions may include one or more separate programs, each including an ordered list of executable instructions for implementing logical functions. When executed by the wiring assembly processor 130, the decoding instructions receive and process signals from various circuits present in the wiring assembly controller 126; perform logic, calculations, methods, and / or algorithms to drive the status light 132; and, depending on a fault detected by the wiring assembly controller 126 (if any), change the modulation of the light emitted by the status light 132.

[0103] In each aspect, the vision processing module 24 in the electric vehicle 100 executes decoding instructions to decode the encoded, modulated light L emitted by the wire assembly controller 126. Figure 6The illustration shows aspects of a method implemented when executing decoding instructions to identify a fault detected by the wiring harness controller 126. Method 300 begins at block 302, where a request for charging is detected. This request can be initiated by plugging the vehicle adapter 120 into the electric vehicle 100. At block 304, the vision processing module 24 activates the light sensor 18. At block 306, the vision processing module 24 uses the light sensor 18 to identify the wiring harness controller 126 or light emitted from the status light 132 of the wiring harness controller 126. At block 308, the vision processing module 24 decodes the modulation of the light L emitted by the status light 132, and at block 310, the vision processing module 24 displays the cause of the fault on the display 20.

[0104] In an additional or alternative aspect, the external visual processing module 152 of the external diagnostic visual instrument executes instructions to decode the coded light emitted by the wire assembly controller 126. Figure 7 The illustration shows aspects of a method implemented in an application that executes instructions to decode a fault detected by the wire assembly controller 126. Method 400 begins at block 402, where the application is enabled by a user in an external diagnostic visualizer 150. At block 404, the external vision processing module 152 enables the external light sensor 154. At block 406, the external vision processing module 152 utilizes the external light sensor 154 to identify the wire assembly controller 126 or light emitted from the status light 132 of the wire assembly controller 126. At block 408, the external vision processing module 152 decodes the modulation of the light L emitted by the status light 132, and at block 410, the external vision processing module 152 displays the cause of the fault on an external display 156.

[0105] As described above, fault data captured from the wiring assembly 104 by the electric vehicle 100 or the external diagnostic visualization device 150 can be transferred by the communication systems 30, 160 to the external entity 32 (including those external entities mentioned above and the data center) for the purpose of identifying and tracking faults identified by the given wiring assembly controller 126. Figure 8The diagram illustrates a method for conveying fault information. Method 800 begins at block 802, where a fault, such as that conveyed by the wiring assembly controller 126, is identified by either the electric vehicle 100 or the external diagnostic visualizer 150. At block 804, the wiring assembly 104 is identified by either the electric vehicle 100 or the external diagnostic visualizer 150, in addition to other identification information and any environmental factors that can be monitored by either the electric vehicle 100 or the external diagnostic visualizer 150 (such as the temperature of the environment where the wiring assembly 104 is located). At block 806, the location of the wiring assembly 104 is identified by either the electric vehicle 100 or the external diagnostic visualizer 150. At block 808, information about the fault is transferred to an external entity 32 (such as one or more data centers), where faults 810 related to the wiring assembly 104 and faults 812 related to infrastructure (i.e., household electrical wiring) are stored. Fault transfer can occur via any of several communication protocols, including but not limited to the Internet, via a telemetry module present in the electric vehicle 100, or wirelessly via communication protocols (including 802.11, Bluetooth, cellular communication, etc.). At block 814, these faults are made accessible to engineers, suppliers, dealers, and repair shops to assist in resolving identified faults.

[0106] The system and process disclosed herein for providing indication of wiring assembly fault status offer several advantages. These advantages may include the ability to effectively communicate the presence of a fault and, if present, the approximate location of the problem causing the fault. These advantages may further include reduced warranty claims because it allows for the identification of the source of the fault, including whether the fault is within the wiring assembly, vehicle, or home electrical wiring system (including in GFCI outlets), saving both money and time for both the user and the wiring assembly supplier. These advantages further include the ability to receive and review transmitted diagnostic data on smartphones and vehicle interface terminals.

[0107] The description in this disclosure is exemplary in nature only, and variations thereof without departing from the spirit and scope of this disclosure are intended to remain within its scope. Such variations shall not be considered as departing from the spirit and scope of this disclosure.

Claims

1. An electric vehicle wiring assembly, comprising: Wire assembly controller, the wire assembly controller comprising: Wire assembly processor, Multiple fault detection circuits are connected to the wire assembly processor, and A first status light, which is connected to the wiring assembly processor. The wire assembly processor is configured as follows: A fault is identified in at least one of the plurality of fault detection circuits. Terminate the power supply to the wire assembly. Turn on the first status light indicating the presence of the fault, and The fault is encoded in the first status light by modulating the first status light. The fault is coded by changing the duty cycle of the first status light, and The time period for calibrating the duty cycle is determined by the frame rate of the light sensor, such that the light emitted by the first status light can be detected by the light sensor but cannot be distinguished by the user. The light sensor is associated with at least one of the electric vehicle and an external diagnostic visualization device.

2. The electric vehicle wiring assembly of claim 1, further comprising a wiring assembly cable, the wiring assembly cable including a vehicle adapter at a first end of the wiring assembly cable and a wiring system adapter at a second end of the wiring assembly cable, wherein, The wire assembly controller is connected to the wire assembly cable.

3. The electric vehicle wiring assembly according to claim 1, wherein, The plurality of fault detection circuits include one or more of the following: a power plug overheat detection circuit, a ground fault detection circuit, a power plug ground loss detection circuit, and a controller internal failure detection circuit.

4. The electric vehicle wiring assembly according to claim 1, wherein, The wire assembly processor is further configured to: cut off a second status light indicating that the wire assembly is charging.

5. The electric vehicle wiring assembly according to claim 4, wherein, The second status light is green, and the first status light is amber.

6. A system for identifying faults in wiring assemblies of electric vehicles, the system comprising: Wire assembly controller, the wire assembly controller comprising: Wire assembly processor, Multiple fault detection circuits are connected to the wire assembly processor, and A first status light, which is connected to the wiring assembly processor. The wire assembly processor is configured to: identify a fault in at least one of the plurality of fault detection circuits, terminate power to the wire assembly, turn on a first status light indicating the presence of the fault, and encode the fault in the first status light by modulating the first status light; and Electric vehicles, the electric vehicles including: First vision processing module, A first light sensor, which is connected to the first vision processing module, and A first display is connected to the first visual processing module. In this configuration, the first light sensor is configured to detect light emitted by the first status light, the first vision processing module is configured to decode the fault encoded in the modulated first status light, and the first display is configured to display the fault decoded by the first vision processing module. The fault is coded by changing the duty cycle of the first status light, and The time period for calibrating the duty cycle is determined by the frame rate of the first optical sensor, so that the light emitted by the first status light can be detected by the first optical sensor but cannot be distinguished by the user.

7. The system for identifying faults in wiring assemblies of electric vehicles according to claim 6, wherein, The plurality of fault detection circuits include one or more of the following: a power plug overheat detection circuit, a ground fault detection circuit, a power plug ground loss detection circuit, and a controller internal failure detection circuit.

8. The system for identifying faults in wiring assemblies of electric vehicles according to claim 6, wherein, The wire assembly processor is further configured to: cut off a second status light indicating that the wire assembly is charging.

9. The system for identifying faults in wiring assemblies of electric vehicles according to claim 6, further comprising a communication system, wherein, The communication system is configured to transfer the fault to an external entity.

10. The system for identifying faults in wiring assemblies of electric vehicles according to claim 6, further comprising an external diagnostic visualization device.

11. The system for identifying faults in wiring assemblies of electric vehicles according to claim 10, wherein, The external diagnostic visualization device includes: External vision processing module, An external light sensor, which is connected to the external vision processing module, and An external display, which is connected to the external vision processing module, The external light sensor is configured to detect light emitted by the first status light, the external vision processing module is configured to decode the fault encoded in the modulated first status light, and the external display is configured to display the fault decoded by the external vision processing module.

12. The system for identifying faults in wiring assemblies of electric vehicles according to claim 10, wherein, The external diagnostic visualization device includes an external communication system configured to transfer the fault to an external entity.

13. The system for identifying faults in wiring assemblies of electric vehicles according to claim 10, wherein, The external diagnostic visualization device is a smartphone.

14. The system for identifying faults in wiring assemblies of electric vehicles according to claim 10, wherein, The external diagnostic visualization device is a diagnostic unit.

15. A method for identifying faults in wiring assemblies of electric vehicles, the method comprising: Faults in the wire assembly are identified by using fault detection circuitry included in the wire assembly controller. Terminate the power supply to the wire assembly; The presence of the fault is indicated by a first status light in the wire assembly controller. The fault is encoded in the first status light by modulating the first status light using a wire assembly processor included in the wire assembly controller; as well as The first light sensor is used to detect the light emitted by the first status light. The fault is coded by changing the duty cycle of the first status light, and The time period for calibrating the duty cycle is determined by the frame rate of the first optical sensor, so that the light emitted by the first status light can be detected by the first optical sensor but cannot be distinguished by the user.

16. The method of claim 15, further comprising: The fault encoded in the first status light is decoded using a first vision processing module, and the fault decoded by the first vision processing module is displayed using a first display.

17. The method of claim 16, further comprising: The fault is transferred to an external entity using a first communication system.

18. The method of claim 15, further comprising: An external light sensor is used to detect the light emitted by the first status light, an external vision processing module is used to decode the fault encoded in the first status light, and an external display is used to display the fault decoded by the external vision processing module.

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