Charging coupler for coupling electric vehicle (EV) to electric vehicle power supply and method of operation thereof

Abstract

Embodiments of the present disclosure relate to a charging coupler for coupling an electric vehicle (EV) to an electric vehicle power supply device and a method of operating the same. A charging connector (10) for an electric vehicle supply equipment (EVSE), the charging connector (10) comprising: a primary contact element (12) and a secondary contact element (14) for electrically connecting to a counter coupler contact element (24) of a counter coupler (11) of an electric vehicle (EV) when the charging connector (10) and the counter coupler (11) are interconnected; an insulating element (16) which electrically isolates the primary contact element (12) and the secondary contact element (14) from each other; and a measurement circuit (18) configured to measure an electrical parameter of an electrical path (20) formed by the primary contact element (12), the counter coupler contact element (24) and the secondary contact element (14) when the charging connector (10) and the counter coupler (11) are connected to each other.

Description

Technical Field

[0001] Embodiments of the present disclosure relate to a charging coupler for coupling an electric vehicle (EV) to electric vehicle supply equipment (EVSE). The charging coupler may be an EVSE connector or an EV inlet. Embodiments of the present disclosure also relate to a method for charging an electric vehicle using the charging coupler. Background Art

[0002] For the adoption of electric vehicle technology, such as electric buses or vehicles, the evolution of charging systems represents a key element. When entering the complexity of DC fast charging, the focus on improving both efficiency and safety continues to grow. Central to this goal is the timely detection and elimination of problems associated with poor connector contact. These problems may be caused by contamination or dirtiness of electrical contacts resulting in poor or unreliable electrical connections. This problem may lead to overheating of electrical contacts due to increased resistance or more generally increased electrical impedance. If not addressed, such conditions may lead to overheating and may result in a significant risk of overheating and damage to vehicle components. Another problem may be that the electrical connection cannot be established due to excessively high electrical impedance, which may be the case for contacts used for communications and the like. Similarly, for contacts used for safety, such as protective earthing, it is important to ensure that contact is reliably established.

[0003] The demand for advanced solutions in this area demonstrates the continued evolution of electric vehicle infrastructure and underscores the need for advanced technologies to ensure a safe and efficient charging experience.

[0004] Terms and Definitions

[0005] The terms used in this application are briefly explained as follows.

[0006] Electric vehicle supply equipment (EVSE) is a hardware and software system that provides electrical energy for charging electric vehicles (EVs). It specifically includes charging stations. The EVSE has a charging connector that can be connected to the corresponding inlet of the EV to establish an electrical connection for charging the EV. In addition to the electrical connection, it can also provide a communication link and other functions, such as a protective ground contact. The term "charging coupler" can refer to either the EVSE charging connector or the EV inlet, and the term "counter coupler" can refer to the other.

[0007] In this document, "or" is understood as a non-exclusive disjunction. Thus, the expression "A or B" means that at least one of the statements A and B is true. Alternatively, the expression "A or B" is understood as the interpretation of feature B on feature A.

[0008] As used herein, the terms "substantially," "essentially," or "approximately" generally mean that there may be a certain deviation, for example, up to 1%, up to 3%, or up to 10% deviation from the characteristic expressed as "substantially," "essentially," or "approximately." Summary of the Invention

[0009] In view of the above, a charging coupler for coupling an electric vehicle (EV) to electric vehicle supply equipment (EVSE) is provided according to claim 1 , and a method is provided according to claim 12 .

[0010] According to one aspect of the present disclosure, a charging coupler is provided for coupling an electric vehicle (EV) to electric vehicle supply equipment (EVSE) by connecting the charging coupler to an opposing coupler. The charging coupler can be an EVSE connector, which is a component of the EVSE, in particular a component of the charging station, through which the EVSE is electrically connected to the electric vehicle, in particular to the inlet (opposing coupler) of the EV. Alternatively, the charging coupler can be an EV inlet, through which the EV is electrically connected to the EVSE, in particular to the connector (opposing coupler) of the EVSE. In both cases, the main function of the charging coupler (and opposing coupler) is to safely transfer electrical power from the charging station to the EV and ultimately to the EV battery.

[0011] The charging coupler comprises a primary contact element and a secondary contact element for electrically connecting to a (single) opposing coupler contact element of the opposing coupler when the charging coupler and the opposing coupler are connected to each other. In particular, the primary contact element and the secondary contact element may belong to the charging coupler contacts of the connector and / or may have the same phase or polarity. For other phases or polarities, and for other functions such as grounding or communication, the charging coupler may comprise additional charging coupler contacts. At least some of these additional charging coupler contacts may also have (multiple) primary and secondary contact elements as described herein.

[0012] The charging coupler (more specifically, its charging coupler contacts) further includes an insulating element that electrically isolates the primary contact element from the secondary contact element. This has the effect of preventing direct electrical contact between the primary contact element and the secondary contact element, which advantageously facilitates the electrical measurements described herein. The insulating element does not imply complete galvanic isolation between the primary contact element and the secondary contact element. For example, the primary contact element and the secondary contact element may be electrically connected to each other via a measurement circuit, which is described further below. In certain embodiments, the primary contact element and the secondary contact element may not be directly electrically connected to each other, and / or they may be electrically connected to each other only via the measurement circuit.

[0013] The charging coupler also includes a measurement circuit configured to measure electrical parameters of an electrical path formed by the primary contact element, the counter-coupler contact element, and the secondary contact element when the charging coupler and the counter-coupler are connected to each other (when the primary contact element and the secondary contact element are connected to the counter-coupler contact element). The measurement circuit is a circuit within the charging coupler that is configured to measure electrical parameters, particularly electrical parameters such as voltage, current, and impedance (particularly resistance). The electrical path is a closed loop through which current can flow. The measurement circuit and the electrical path may include components and paths that are also used for other purposes, such as for charging an EV.

[0014] According to another aspect of the present disclosure, there is provided an EVSE including the charging coupler described herein.

[0015] According to another aspect of the present disclosure, a method for charging an electric vehicle using a charging coupler or EVSE as described herein is provided. The method includes connecting the charging coupler and a counter coupler to each other, thereby electrically connecting the primary contact element and the secondary contact element to the counter coupler contact element of the counter coupler; and measuring, by a measurement circuit, an electrical parameter of an electrical path formed by the primary contact element, the counter coupler contact element, and the secondary contact element.

[0016] The embodiments described herein allow monitoring and assessment of the quality and integrity of electrical connections. By measuring electrical parameters along the electrical path, information about the quality of the electrical connection (e.g., electrical impedance, in particular contact resistance) between the primary contact element and the opposing coupler contact element and / or between the secondary contact element and the opposing coupler contact element can be obtained. This allows detection of problems such as poor contact or potential failures during charging, thereby improving the safety and efficiency of EV charging.

[0017] The embodiments described herein introduce a safe and effective mechanism to detect and / or prevent operation using poor electrical contacts by providing appropriate measurement conditions of electrical parameters along the charging path. Thus, it helps improve the safety and efficiency of electric vehicle (EV) charging systems, thereby reducing risks and increasing the reliability and efficiency of the EV charging process.

[0018] Further aspects, advantages and features of the present disclosure are apparent from the dependent claims, the description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to understand in detail the manner in which the above-described features of the present disclosure are described, the present disclosure briefly summarized above may be described in more detail with reference to exemplary embodiments. The accompanying drawings relate to embodiments of the present disclosure and are described as follows:

[0020] Figure 1 A schematic diagram showing a top view of a socket connector arrangement that complies with MCS (Megawatt Charging System) requirements;

[0021] Figure 2 shows a schematic diagram of a charging connector arranged for interacting with an inlet in accordance with embodiments described herein;

[0022] Figure 3 A flow chart illustrating a method of charging an electric vehicle according to embodiments described herein; and

[0023] Figure 4-Figure 5 Embodiments of a charging connector for interacting with an inlet, arranged according to further embodiments described herein, are respectively shown. DETAILED DESCRIPTION

[0024] Reference will now be made in detail to various embodiments, with one or more examples of the embodiments illustrated in each figure. Each example is provided by way of explanation and is not intended to be limiting. For example, a feature illustrated or described as part of one embodiment may be used on any embodiment or in combination with any other embodiment to produce another embodiment. The present disclosure is intended to include such modifications and variations. The present disclosure is intended to include such modifications and variations. In particular, details illustratively explained with reference to any figure should not be construed as being limited to elements of these figures. On the contrary, these details may also be combined with other embodiments illustratively explained with reference to other figures.

[0025] In the following description of the figures, the same reference numerals refer to the same or similar components. Generally, only the differences with respect to the individual embodiments are described.

[0026] The reference numbers in the figures are used for illustration only. The aspects of the present invention are not limited to any particular embodiment. Instead, unless otherwise stated, any aspect or embodiment described herein may be combined with any other aspect or embodiment described herein.

[0027] In the following description, the charging coupler 10 is shown as an EVSE connector for an EVSE. Accordingly, the counter coupler 11 is shown as an EV inlet for an EV. This particular example is chosen for simplicity and clarity, without loss of generality. It will be appreciated that the same description also applies to the reverse case, where the charging coupler is the EV inlet and the counter coupler is the EVSE connector.

[0028] Figure 1A schematic diagram shows the geometry of an EVSE connector 10 that complies with MCS (Megawatt Charging System) requirements. Connector 10 has two DC charging contacts (DC+, DC-), a protective earth (PE), two communication lines (Comm.), and two CCS-compliant pins (CP, PP). Connector 10 is part of a power supply device (specifically, an EVSE, and more specifically, a vehicle charging station) and is adapted to be connected to a corresponding inlet of an electric vehicle.

[0029] The DC+ and DC- connector contacts of connector 10 are designed to be connected to the positive and negative terminals of the vehicle battery, respectively, via corresponding contacts of the EV inlet, providing the battery with positive and negative voltages of DC power.

[0030] Figure 2 An embodiment of a charging connector 10 arranged to interact with an inlet 11 on the vehicle side is shown. Specifically, a single connector contact (DC+ or DC-) of the connector 10 is shown, and correspondingly a single inlet contact (inlet contact element) 24 of the EV inlet 11 is shown. Thus, the charging connector 10 may have Figure 2 A pair of connector contacts shown in and / or described herein are used to contact a corresponding pair of EV inlet contacts of the EV inlet 11 .

[0031] Figure 2 Shown is a configuration when the charging connector 10 and the EV inlet 11 are connected to each other, and thus is a configuration when the connector contacts and the inlet contacts (inlet contact elements) 24 are mated with each other.

[0032] Figure 2 The charging connector 10 shown in FIG (in particular, its connector contacts) has a primary contact element 12 and a secondary contact element 14 for electrically connecting to different surface portions of the inlet contact element 24 of the inlet 11. Furthermore, an insulating element 16 electrically isolates the primary contact element 12 and the secondary contact element 14 from each other. Providing such an insulating element 16 is not incompatible with the MCS standard.

[0033] The insulating element 16 allows the creation of Figure 2 . The measuring circuit 18 measures the resistance of an electrical path 20 formed by the primary contact element 12, the inlet contact element 24, and the secondary contact element 14 (which is closed into a closed loop by the measuring circuit 18). The measuring circuit 18 has two terminals connected to the primary contact element 12 and the secondary contact element 14, respectively, and an impedance measuring device 19 connecting the two terminals to each other.

[0034] Impedance measurement device 19 can be implemented in various known ways, such as by connecting a voltage source in parallel with the current measurement device. Impedance measurement device 19 typically includes a power supply. In addition to impedance measurement device 19, a device for measuring another electrical parameter of electrical path 20 can also be used. The impedance can be DC impedance, impedance at a predetermined frequency, or a response function including multiple frequencies or pulse shapes.

[0035] In one example, a current provided by the measuring device 19 (preferably by its power supply) flows along the electrical path 20 through the area of the primary contact element 12, the secondary contact element 14 and the inlet contact element 24 and returns to the measuring circuit 18, which is thereby adapted to measure a parameter of the electrical path 20, such as electrical impedance (resistance).

[0036] The electrical parameters contain information about the quality of the electrical interface between the connector contacts, in particular the primary contact element 12 and the secondary contact element 14 and the inlet contact element 24 thereof, in particular information about the contact impedance (contact resistance).

[0037] Figure 3 The use described herein and for example in Figure 1 and Figure 2 10. A flowchart of a method 100 for charging an electric vehicle using the charging connector 10 shown in FIG. The method 100 includes connecting 102 the charging connector 10 and the EV inlet 11 to each other, thereby electrically connecting the primary contact element 12 and the secondary contact element 14 to the inlet contact element 24 of the EV inlet 11; and measuring 104 an electrical parameter of the electrical path 20 formed by the primary contact element 12, the inlet contact element 24, and the secondary contact element 14 via the measurement circuit 18. The method may also optionally include adaptively controlling 106 an operating condition of the EVSE based on the measured electrical parameter.

[0038] The measurement of resistance / conductivity refers to the efficiency with which a material allows electric current to flow, thereby allowing the efficiency and power dissipation in an electrical circuit to be determined. The measurement of current can be used to determine the operating capacity of electrical power equipment and to ensure adequate power delivery. Voltage measurements can be used to ensure that electrical equipment receives the amount of power required to operate. The impulse response describes how an electrical system responds to an external stimulus (such as a short electrical pulse) over time, and its measurement can provide insight into the stability and dynamic behavior of an electrical system under transient conditions, particularly in response to fault sources that generate currents of different frequencies. The transfer function describes how an electrical system processes an input signal to produce an output and reflects the system behavior in the frequency domain, allowing the system to be analyzed to achieve desired output characteristics, particularly in response to fault sources that generate currents of different frequencies. The frequency characteristics provide details of how the system response varies with different signal frequencies, allowing the system performance to be improved in response to fault sources that cause currents of different frequencies.

[0039] By providing an insulating element 16 between the primary contact element and the secondary contact element, implementations for various measuring circuits can be obtained, Figure 2 The circuit shown in is only one example. In particular, the principle for measuring impedance described in EP 3471991A1 (EP'991) can be used, although the hardware implementation is very different, the content of which is incorporated herein by reference in its entirety. The primary contact element 12 and secondary contact element 14 of the present invention correspond to the primary contact elements 22, 23, 24 and secondary contact elements 28, 128, 228 of EP'991; the inlet contact element 24 of the present invention corresponds to the contact elements 32, 33, 34 of EP'991.

[0040] For example, the above Figure 2 The measurements shown in the diagram correspond to those of EP'991 Figure 3 The contents and descriptions of which are incorporated herein by reference.

[0041] also, Figure 4 The measurements shown in the diagram correspond to those of EP'991 Figure 5 The contents and descriptions thereof are incorporated herein by reference.

[0042] also, Figure 5 The measurements illustrated in correspond to those in FIG. 6 of EP '991, the content and description of which are referred to and incorporated herein by reference.

[0043] according to Figure 4 In the embodiment shown in FIG, during charging, current I flows from the EVSE through the primary contact 12 and the inlet contact (inlet contact element) 24. Furthermore, the inlet contact element 24 is also in contact with the secondary contact element 14. Thus, a (first) current path runs directly from the primary contact element 12 to the inlet contact element 24. Furthermore, an electrical path 18 leads from the primary contact element 12 via the inlet contact element 24 to the secondary contact element 14, with this loop being closed by a voltage measuring device 19. To determine the impedance, the voltage measuring device 19 measures the voltage between the primary contact element 12 and the secondary contact element 14.

[0044] Figure 5 Another embodiment is shown in which the two (upper and lower, i.e., positive and negative) connector contacts of the connector 10 are electrically isolated from each other and preferably physically separated by a distance from each other. The connector contacts can be arranged on a mounting base 30 that physically supports the charging connector 10 and provides electrical insulation.

[0045] The inlet contacts 24 have a design complementary to the connector contacts and are arranged to mate with the connector contacts.The inlet contacts 24 may be arranged on a mounting base 32 that physically supports them and provides electrical insulation therebetween.

[0046] Figure 5 The left portion of FIG shows a power source 34 of the EVSE having a positive and a negative pole and adapted to provide electrical power to the EV battery 36. The positive pole is connected to the upper connector contact of the charging connector 10, while the negative pole is connected to the lower connector contact of the charging connector 10. The upper connector contact (specifically, its primary contact element 12) is adapted to provide a DC+ voltage, while the lower connector contact (specifically, its primary contact element) is adapted to provide a DC- voltage to the vehicle battery 36 via the corresponding inlet contact 24 of the inlet 11.

[0047] The other part of the measuring circuit 18 is connected between the secondary contact elements of the two connector contacts and comprises a voltmeter 19 .

[0048] exist Figure 5 In an embodiment of the present invention, a first (upper) connector contact and a second (lower) connector contact are used to measure the contact impedance of the electrical contact. Figure 5 In the example shown in FIG, a first connector contact arrangement has a primary contact element 12 and a secondary contact element 14. The second (lower) connector contact also has a primary contact element and a secondary contact element. In order to charge the battery of the electric vehicle or any other suitable energy storage device 36, the energy storage device 36 is electrically connected to the inlet contact 24. In addition, a power supply 34 is electrically connected to the primary contact elements of the first and second connector contacts. In order to measure the contact impedance of the electrical contact between the connector contacts and the corresponding inlet contacts, the secondary contact element 14 of the first connector contact and the secondary contact element of the second connector contact are electrically connected to a voltage measuring device 19. By measuring the voltage with the voltage measuring device 19 at a given current provided by the power supply 34, the impedance can be determined.

[0049] Other aspects:

[0050] Next, some additional optional general aspects are described. The reference numerals are provided for illustration only and are not intended to limit any particular figure shown herein. Each of these aspects can be combined with any other aspect or embodiment described herein unless inconsistent with each other.

[0051] As already indicated above, in the following, the charging coupler is the EVSE connector and the counter coupler is the EV inlet, but this identification is intended to be without loss of generality. Therefore, the present disclosure is more generally applicable to any situation where the described EVSE connector is any charging coupler and the EV inlet is any counter coupler.

[0052] First, various aspects related to the connector and / or inlet will be described. According to one aspect, the primary contact element 12 has a radially inward contact surface and can be a tubular (e.g., tulip-shaped) contact. According to one aspect, the secondary contact element 14 has a radially outward contact surface and can be a needle-shaped or feeder contact. Similarly, blade-type contacts are also possible, for example, the opposing coupler contact element is a blade sandwiched between the primary and secondary contact elements.

[0053] According to a further aspect, the primary contact element 12 and the secondary contact element 14 are arranged coaxially relative to each other, the secondary contact element 14 being preferably arranged coaxially within the primary contact element 12. According to one aspect, the primary contact element 12 and the secondary contact element 14 have surface portions facing each other and are arranged for receiving a portion of the inlet contact element 24 therebetween.

[0054] According to one aspect, the inlet contact element 24 is a tubular piece having an inner surface and an outer surface, and the primary contact element 12 and the secondary contact element 14 are adapted to contact the outer surface and the inner surface of the inlet contact element 24, respectively.

[0055] According to one aspect, the primary contact element 12 and the secondary contact element 14 are first connector contacts (e.g., having a first polarity; specifically, the first connector contact having a first polarity) of the charging connector 10, and the inlet contact element 24 is the first inlet contact (having a first polarity). The charging connector 10 also includes a second connector contact, and the EV inlet 11 includes a second inlet contact, the second connector contact and the second inlet contact having a second polarity opposite to the first polarity. The second connector contact can have a similar structure to the first connector contact and specifically include similar elements as the first connector contact. For example, when the charging connector 10 and the EV inlet 11 are connected to each other, the primary contact element 12 and the secondary contact element 14 of the second connector contact are configured to electrically connect to (different surface portions of) the second inlet contact (inlet contact element) 24 of the EV inlet 11. The insulating element 16 of the second connector contact can electrically isolate the primary contact element 12 and the secondary contact element 14 of the second connector contact from each other.

[0056] According to one aspect, the inlet contact element 24 is electrically conductive.The inlet contact element 24 may be a single contact element and / or a single electrically conductive structure, such as a single metal piece.

[0057] According to one aspect, when the charging connector 10 and the electric vehicle inlet contact (inlet contact element 24) are connected to each other, the primary contact element 12 and the secondary contact element 14 are arranged to directly contact different surface portions of the inlet contact element 24. According to one aspect, the secondary contact element 14 is arranged (preferably coaxially) within the primary contact element 12.

[0058] According to one aspect, the insulating element 16 forms an insulating barrier along a surface portion of the charging connector 10 between the primary contact element 12 and the secondary contact element 14 .

[0059] According to one aspect, the charging connector 10 comprises at least one contact cavity accommodating a primary contact element 12 and a secondary contact element 14 .

[0060] According to one aspect, the primary contact element 12 and the secondary contact element 14 may be arranged to electrically contact a single inlet contact element 24 when the charging connector 10 and the electric vehicle inlet are connected to each other.

[0061] According to one aspect, the secondary contact element 14 may be arranged (preferably coaxially) within the primary contact element 12 .

[0062] According to one aspect, the connector contact(s) are at least one electrical contact from the following list: a negative DC contact, a positive DC contact, a control contact, and a protective earth contact.

[0063] According to one aspect, the connector complies with a charging standard such as SAE J3271 or IEC 63379. According to one aspect, the connector is an MCS connector.

[0064] Next, various aspects related to measurement and / or charging of electrical parameters are described.

[0065] According to one aspect, the electrical parameter indicates an impedance, in particular an impedance of an electrical path, and in particular an electrical contact resistance between the primary contact element 12 and the inlet contact element 24 and / or between the secondary contact element 14 and the inlet contact element 24 .

[0066] According to one aspect, the measuring circuit 18 comprises a circuit connected to the primary contact element 12 via a primary contact element terminal and to the secondary contact element 14 via a secondary contact element terminal.

[0067] According to one aspect, the measurement circuit 18 is adapted to measure the voltage drop across at least one of: a) the interface between the primary contact element 12 and the inlet contact element 24, or b) the interface between the secondary contact element 14 and the inlet contact element 24, or c) both in series.

[0068] According to one aspect, the measurement circuit 18 is configured to apply a switched current or a pulsed current during the measurement of the electrical parameter.

[0069] According to one aspect, the measuring circuit 18 comprises a measuring device 19, such as a voltmeter, an ohmmeter, or a multimeter. According to one aspect, the electrical parameter is indicative of or correlated to an electrical path resistance along the electrical path 20, in particular to an electrical contact resistance between the primary contact element 12 and the inlet contact element 24 and / or between the secondary contact element 14 and the inlet contact element 24, the electrical parameter in particular comprising at least one of the following: resistance or conductivity, current, voltage, frequency characteristics.

[0070] According to one aspect, the primary contact element is connected to a power source for providing a charging current to the EV via the inlet contact element 24. According to one aspect, the connector is adapted to apply a current of at least 10 A during measurement of the electrical impedance.

[0071] According to one aspect, the EVSE is configured for DC charging, and / or its connector is a DC connector for DC charging.

[0072] Next, various aspects related to the control of the EVSE are described.

[0073] According to one aspect, the EVSE includes a power supply configured to charge the EV via a connector 10, and in particular, via at least a primary contact element. The power supply may be a DC power supply, i.e., delivering electrical DC power to the connector. The power supply may be configured to apply a switched current or a pulsed current during measurement of an electrical parameter.

[0074] According to one aspect, the EVSE may further include a controller adapted to monitor electrical parameters. The controller may be configured to:

[0075] - identifying an anomaly in an electrical parameter, in particular by comparing the electrical parameter with a predetermined threshold value; and preferably for outputting a warning message when an anomaly is detected based on the electrical parameter;

[0076] -Adjusting the EV's charging operation by the EVSE when an anomaly is detected based on electrical parameters;

[0077] - Implementing a feedback mechanism suitable for triggering an action when an electrical parameter is determined to be outside a specified operating range,

[0078] -Control charging power according to electrical parameters.

[0079] Thus, the controller may be particularly configured to implement a feedback mechanism adapted to trigger an action upon determining that an electrical parameter is outside a specified operating range, and / or to control the charging power in dependence on the electrical parameter.

[0080] According to one aspect, the controller may be adapted to identify an anomaly in the electrical parameter(s), for example by detecting whether a resistance determined from the measured electrical parameters exceeds a predetermined threshold. Such an anomaly may indicate a problem such as a poor connection or a fault in the charging system. The controller may be adapted to output a warning message when an anomaly is detected. The warning message may be sent to a central control or management system, for example, via a network. The warning message may be output to an operator. The controller may be adapted to adjust the charging process when an anomaly is detected, for example by limiting the charging current / charging power, or by interrupting or terminating the charging process. Thus, the controller may be adapted to perform diagnostic functions, including notification of system warnings or service requirements.

[0081] According to one aspect, in response to measurements, such as at least one of: fluctuations in electrical parameters of the electrical path 20 and / or supply voltage and / or current demand during charging and / or environmental conditions such as temperature / humidity; and changes in the state of the electric vehicle battery 36, the controller can be adapted to adaptively control operating conditions related to different states and parameters of operation of the charging connector 10, such as at least one of: operating mode; power output level; charging rate; alert transmission.

[0082] A method for charging an electric vehicle using the charging connector 10 and / or EVSE described herein is also provided. The method includes connecting the charging connector 10 and the EV inlet 11 to each other, thereby electrically connecting the primary contact element 12 and the secondary contact element 14 to the inlet contact element 24 of the EV inlet 11; and measuring, by a measurement circuit 18, an electrical parameter of an electrical path 20 formed by the primary contact element 12, the inlet contact element 24, and the secondary contact element 14. The method may also include adaptively controlling an operating condition of the EVSE based on the measured electrical parameter.

[0083] According to one aspect, the charging connector 10 may include a controller adapted to monitor and control voltage levels in the charging connector 10 and / or the charging path 20 , thereby enabling control of the charging process to ensure safe and efficient charging of the electric vehicle.

[0084] According to one aspect, the controller can be adapted to implement a feedback mechanism that triggers an alarm or action upon detecting unsafe electrical parameters (such as voltage levels and / or current / resistance values). That is, charging connector 10 can be adapted to continuously estimate electrical parameters along charging path 20, such as voltage, current, and resistance. If these parameters deviate from predefined safety limits, the controller feedback mechanism is activated. This activation can result in a variety of responses, ranging from triggering an alarm to initiating corrective action. This functionality allows for avoiding potential hazards associated with electrical faults, thereby ensuring safe and reliable system operation.

[0085] According to one aspect, the controller can be adapted to control the charging current based on the electrical parameters and / or temperature of the charging path 20, preferably enabling adaptive control of the charging process based on real-time temperature data. That is, the controller can be configured to dynamically adjust the charging current based on two key factors: the electrical characteristics of the electrical path 20 and the ambient temperature. By integrating real-time temperature data, the controller can adaptively adjust the charging process. This approach ensures that the charging current is optimized for both efficiency and safety, while accounting for variations in ambient conditions and electrical path characteristics. This enables a more responsive and intelligent charging system that can adapt to different scenarios, improving the effectiveness and reliability of the charging process.

[0086] According to one aspect, the EVSE includes measurement circuitry 18 configured to measure electrical path parameters, thereby enabling monitoring and assessment of the quality and integrity of the electrical connection. By measuring parameters along the electrical path 20, problems such as poor connections or potential faults during charging can be detected, thereby improving the safety and efficiency of EV charging.

[0087] According to one aspect, the method can include detecting anomalies or fluctuations in electrical path parameters, which can indicate issues such as a poor connection or fault in the charging system. Prompt detection and warning of such anomalies allows for early intervention to prevent further complications or damage to the charging system. This proactive approach ensures a more stable and safer charging process, protecting both the device and the vehicle being charged.

[0088] According to one aspect, the method may include performing diagnostic functions, including notifying the system of warnings or service requirements. Providing timely alerts and service reminders may allow for proactive resolution of potential problems, reducing downtime and extending the useful life of the system, thereby ensuring continued and efficient operation and / or improving system maintenance and reliability.

[0089] According to one aspect, the method may include adaptively controlling operating conditions associated with different states and parameters of charger operation, such as at least one of: operating mode; power output level; charging rate; and alert transmission, in response to measured values, such as at least one of: fluctuations in electrical parameters of the charging path 20 and / or supply voltage and / or current demand during charging and / or environmental conditions such as temperature / humidity; changes in the state of the electric vehicle battery 36.

[0090] Preferably, such adaptive control can allow adjustments to be made based on real-time data from various sources (such as electrical path fluctuations, power supply conditions, etc.), thereby automatically modifying operating parameters to adapt to the current needs of the system and electric vehicle, thereby beneficially improving the charging process in real time to respond to changing conditions and requirements and / or improve overall performance and reliability.

[0091] According to embodiments described herein, electrical path parameters may include at least one of: electrical impedance (eg resistance or conductivity), current, voltage, impulse response, transfer function, frequency characteristics.

[0092] According to one aspect, a controller for a charging connector / EVSE may further include a network interface for connecting the controller to a data network, in particular a global data network (such as the Internet). The controller is operatively connected to the network interface for executing commands received from the data network. The commands may include control commands for controlling the EVSE charging operation. The controller is then adapted to operate the EVSE according to the received control commands. The commands may include status requests. In response to the status request, or in the absence of a previous status request, the controller may be adapted to send status information to the network interface, which is then adapted to send the status information via the network. The status information may particularly include measured electrical parameters (e.g., quantities derived from the electrical parameters).

[0093] (…) The data network may be an Ethernet network using TCP / IP, such as a LAN, WAN, or the Internet. The data network may include distributed storage units, such as a cloud. Depending on the application, the cloud may be in the form of a public cloud, a private cloud, a hybrid cloud, or a community cloud.

[0094] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable a person skilled in the art to practice the described subject matter, including making and using any device or system. The embodiments described herein provide a charging connector for an electric vehicle power supply device, a method of verifying contact between a charging connector and a single inlet contact of an electric vehicle inlet, and the present concept particularly enables safe and efficient charging of electric vehicles. Although various specific embodiments have been disclosed above, the mutually non-exclusive features of the above-described embodiments can be combined with each other. The patentable scope is defined by the claims, and other examples are intended to fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

[0095] Reference numerals

[0096] 10 Charging coupler (EVSE connector)

[0097] 11 Opposite coupler (EV inlet)

[0098] 12 Primary contact elements

[0099] 14 Secondary contact elements

[0100] 16 Insulation elements

[0101] 18 Measurement Circuit

[0102] 19 Measuring device

[0103] 20 electrical paths

[0104] 24 opposed coupler contact elements (entry contacts)

[0105] 30 Mounting base for connector contacts

[0106] 32 Mounting base for inlet contacts

[0107] 34 Power Supply

[0108] 36 Vehicle Batteries

Claims

1. A charging coupler for coupling an electric vehicle (EV) to an electric vehicle supply equipment (EVSE) by connecting the charging coupler (10) to a counter coupler (11), the charging coupler (10) comprising: a primary contact element (12) and a secondary contact element (14) for electrically connecting to a counter-coupler contact element (24) of the counter-coupler (11) when the charging coupler (10) and the counter-coupler (11) are connected to each other; an insulating element (16) for electrically isolating the primary contact element (12) and the secondary contact element (14) from each other; as well as A measuring circuit (18) is configured to measure an electrical parameter of an electrical path (20) formed by the primary contact element (12), the counter-coupler contact element (24), and the secondary contact element (14) when the charging coupler (10) and the counter-coupler (11) are connected to each other.

2. The charging coupler (10) according to claim 1, wherein The charging coupler (10) is an EVSE connector and the counter coupler (11) is an EV inlet, or The charging coupler is an EV inlet and the counter coupler is an EVSE connector.

3. The charging coupling (10) according to claim 1, wherein the primary contact element (12) has a radially inward contact surface and / or the secondary contact element (14) has a radially outward contact surface.

4. The charging coupler (10) according to claim 1, wherein The primary contact element (12) and the secondary contact element (14) are arranged coaxially relative to each other.

5. The charging coupler (10) according to claim 1, wherein The primary contact element (12) and the secondary contact element (14) have surface portions facing each other and are arranged to receive a portion of the opposing coupler contact element (24) therebetween.

6. The charging coupler (10) according to claim 1, wherein The opposed coupler contact element (24) is a tubular member having an inner surface and an outer surface, and wherein The primary contact element (12) and the secondary contact element (14) are adapted to contact the outer surface and the inner surface of the opposing coupler contact element (24), respectively.

7. The charging coupler (10) according to claim 1, wherein The primary contact element (12) and the secondary contact element (14) belong to a first charging coupler contact of the charging coupler (10), and the counter-coupler contact element (24) is a first counter-coupler contact element, wherein the charging coupler (10) further comprises a second charging coupler contact, and the counter-coupler (11) comprises a second counter-coupler contact element.

8. The charging coupler (10) of claim 7, wherein the second charging coupler contact comprises: a primary contact element (12) and a secondary contact element (14) of the second charging coupler contact for electrically connecting to the second counter-coupler contact element (24) of the counter-coupler (11) when the charging coupler (10) and the counter-coupler (11) are connected to each other; and An insulating element (16) of the second charging coupler contact, the insulating element (16) electrically isolating the primary contact element (12) and the secondary contact element (14) of the second charging coupler contact from each other.

9. The charging coupler (10) according to claim 1, wherein The electrical parameter is indicative of an impedance of the electrical path.

10. The charging coupler (10) of claim 1, wherein the measuring circuit (18) is connected to the primary contact element (12) by primary contact element terminals and to the secondary contact element (14) by secondary contact element terminals.

11. The charging coupler (10) of claim 1, wherein the measurement circuit (18) is configured to apply a switching current or a pulsed current during measurement of the electrical parameter.

12. An electric vehicle supply equipment (EVSE), comprising the charging coupler (10) according to claim 1, the charging coupler being an EVSE connector of the EVSE and being adapted to couple the EVSE to the EV by connecting the charging coupler (10) to the counter coupler (11) serving as an EV inlet of the EV.

13. The EVSE of claim 12, further comprising: A power source is configured to charge the EV via at least the primary contact element.

14. The EVSE of claim 12, further comprising: a controller adapted to monitor the electrical parameter, wherein the controller is configured for at least one of: identifying an anomaly in the electrical parameter by comparing the electrical parameter with a predetermined threshold; and outputting a warning message when an anomaly is detected based on the electrical parameter; adjusting, by the EVSE, a charging operation of the EV when an anomaly is detected based on the electrical parameter; implementing a feedback mechanism adapted to trigger an action when the electrical parameter is determined to be outside a specified operating range, The charging power is controlled according to the electrical parameters.

15. An electric vehicle (EV), comprising the charging coupler (10) according to claim 1, the charging coupler being an EV inlet of the EV and being adapted to couple the EV to the EVSE by connecting the charging coupler (10) to the counter coupler (11) being an EVSE connector of the EVSE.

16. A method (100) for charging an electric vehicle using the charging coupler (10) according to claim 1, the method comprising: connecting the charging coupler (10) and the countercoupler (11) to each other, thereby electrically connecting the primary contact element (12) and the secondary contact element (14) to the countercoupler contact element (24); as well as An electrical parameter of an electrical path (20) formed by the primary contact element (12), the opposing coupler contact element (24), and the secondary contact element (14) is measured by the measuring circuit (18).

17. The method (100) of claim 16, further comprising: An operating condition of the EVSE is adaptively controlled based on the measured electrical parameter.

18. The method (100) of claim 16, wherein The opposing coupler contact element (24) is a tubular member having an inner surface and an outer surface and is inserted between the primary contact element (12) and the secondary contact element (14) so that the primary contact element (12) contacts the outer surface of the opposing coupler contact element (24) and the secondary contact element (14) contacts the inner surface of the opposing coupler contact element (24).

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