Method and device for the safe operation of a NACS plug adapter

Abstract

The invention relates to a method for the safe operation of a NACS connector adapter and the associated NACS connector adapter, wherein the connector adapter can assume a locked and an unlocked state. The connector adapter is designed to be positioned between a NACS charging plug (9) and a vehicle. For this purpose, the connector adapter is initially placed in the locked state and thus cannot be connected to a vehicle. In the locked state, the connector adapter can only be connected to the charging plug (9), i.e., on the infrastructure side. The connection between the connector adapter and the charging plug (9) is then checked and detected. If the connection between the connector adapter and the charging plug (9) is successfully detected and checked, the connector adapter is moved to the unlocked state to allow connection of the connector adapter to the vehicle.Once the plug adapter is connected, a vehicle-side locking mechanism is enabled to prevent a disconnection between the plug adapter and the vehicle.

Description

[0001] The present invention relates to a method and a device for the safe operation of a NACS plug adapter.

[0002] A NACS plug adapter (hereinafter referred to as plug adapter) is an adapter which can be plugged between a charging port of the "North American Charging Standard", or NACS for short, and a vehicle to be charged with a charging socket of the "Combined Charging System", or CCS for short.

[0003] NACS charging connectors are common at many charging stations and charging points and are standardized according to SAE J3400. The basis for all charging systems is the IEC 61851 standard, while CCS is standardized according to IEC 62196. Communication between the two systems is functionally identical and standardized according to ISO 15118, using two signal lines: the proximity pilot (PP) and the control pilot (CP). These communication signals are transmitted as electrical signals, each of which can be measured against a ground potential.

[0004] A suitable adapter is necessary if a battery-powered vehicle is equipped with a CCS connector and the vehicle's batteries are to be charged at a charging station or other charging infrastructure with a NACS charging connector. This adapter can then be used between the vehicle and the charging connector to enable charging.

[0005] In the following, safe operation means that personal injury is avoided without the use of power isolation elements.

[0006] An adapter is known from WO 2023 / 205304 A1 which translates the NACS standard into the CCS standard when charging a vehicle. However, safety features are only implemented through a locking mechanism.

[0007] The object of the present invention is therefore to disclose a plug adapter and a method for the safe operation of such a plug adapter. This object is achieved by the features of claim 1.

[0008] The present invention claims a method for the safe operation of a plug adapter. This plug adapter can be arranged between a NACS charging plug (hereinafter referred to as the charging plug) and a vehicle. If the vehicle can be charged according to the NACS standard, the plug adapter is not required. If a vehicle can be charged according to the CCS standard, the plug adapter is arranged on the charging plug of the charging station or charging infrastructure by being pluggable onto the charging plug and also pluggable into the vehicle's charging socket.

[0009] Accordingly, the plug adapter has an infrastructure side, via which it can be plugged into the charging plug, and a vehicle side, via which it can be inserted into the charging socket. Preferably, the plug adapter has sockets on the infrastructure side and pins on the vehicle side.

[0010] The plug adapter can be in a locked or unlocked state. In the locked state, the plug adapter cannot be connected to or disconnected from the vehicle. In the unlocked state, the plug adapter can be inserted into or unplugged from the vehicle's charging socket.

[0011] To achieve these states, the plug adapter includes a movable locking hook, which is preferably mounted on a pivot. The movement of the locking hook can be controlled by a locking mechanism in the plug adapter. The locking mechanism controls the locking hook and can bring about one of the two states of the plug adapter.

[0012] When not in use, the adapter locks into place and cannot be inserted into a vehicle's charging port. To use the adapter and enable charging, it must first be connected to the charging port, such as that of a charging station, via the infrastructure side.

[0013] When locked, the locking hook is not movable and cannot be moved by external force.

[0014] Preferably, depending on the charging infrastructure, it is now necessary for the user to authorize themselves at the charging station so that the charging station can initiate the charging process and generate a corresponding invoice for the user.

[0015] The plug adapter now checks the connection between the plug adapter and the charging plug and initiates a detection process to confirm that the plug adapter has been plugged into a charging plug.

[0016] First, a voltage measurement is taken to determine if there is no voltage present (if voltage is detected, there is a fault in the charging station). Then, a charging process is simulated to determine whether the adapter is connected to an AC or DC charging station. If it is detected that the adapter is connected to an AC station, the locking mechanism for connecting to the vehicle is not released, i.e., it remains locked. This prevents a charging process. Only if a DC charging station is detected is the locking mechanism released, allowing the adapter to be plugged into the vehicle's charging port.

[0017] AC / DC detection can be performed in two ways: 1. An AC charging process is simulated and started via PWM on the CP signal line according to IEC 61851. If the charging station or infrastructure allows this, then it is an AC charging station or wallbox. If it does not, then it can be assumed that it is a DC charging station. 2. A DC charging process is initiated via power line communication on the CP signal line in accordance with DIN EN 70121 or ISO 15118. If this is successful, then it is a DC charging station.

[0018] AC / DC detection was only successful if a DC charging station was detected. Only then was it possible to plug the adapter into the vehicle's charging socket.

[0019] For this voltage measurement, the plug adapter includes a voltage meter and an evaluation unit for detection. The voltage meter is connected to the charging voltage lines and can measure the voltage on these lines and transmit it to the evaluation unit. The evaluation unit is connected to the locking mechanism.

[0020] If detection is unsuccessful, the plug adapter remains locked and optionally disconnects at least the charging voltage lines within the adapter, preventing voltage from reaching the infrastructure side. This ensures protection against accidental contact for the user. The plug adapter is now in a safe state, but charging cannot be initiated in this state. Optionally, the safe state can be indicated visually or audibly.

[0021] For the simulation of a charging process, communication is carried out via a signal line CP in the plug adapter. In addition to the lines for the charging voltage, the plug adapter includes communication lines, namely the "control pilot" (CP) and the "proximity pilot" (PP). A grounding line (PE) is also present.

[0022] For identification via the CP signal line, the plug adapter includes an identification device connected to both the CP signal line and the ground wire. This device measures the voltage on the CP signal line. If the voltage is within an expected range, identification is successful.

[0023] If detection is unsuccessful, the plug adapter remains locked and optionally disconnects at least the charging voltage lines within the adapter, preventing voltage from reaching the infrastructure side. This ensures protection against accidental contact for the user. The plug adapter is now in a safe state, but charging cannot be initiated in this state. Optionally, the safe state can be indicated visually or audibly.

[0024] Optionally, a time window is now waited, which is required for communication according to ISO 15118 to terminate communication on the CP signal line. This time window is needed to be able to abort and restart communication on the CP signal line.

[0025] If all functions of the test are within the expected values, the test is successful.

[0026] If the test fails, the adapter remains locked and optionally disconnects at least the charging voltage lines within the adapter, preventing voltage from reaching the vehicle side. This ensures protection against electric shock for the user. The adapter is now in a safe state, but charging cannot be initiated in this state. Optionally, the safe state can be indicated visually or audibly.

[0027] If the detection and testing are successful, the connection between the charging plug and the plug adapter can optionally be fixed, e.g. by a locking mechanism provided by the plug adapter.

[0028] Also optionally, the connection of the signal lines CP and PP to the charging station is now separated by a separating agent in the plug adapter in order to abort the simulated charging process of the plug adapter and be able to restart it after connecting the vehicle side.

[0029] Afterwards, the plug adapter is moved into the unlocked state, i.e., the locking mechanism of the latching hook is released, allowing the latching hook to swing upwards and enabling insertion into the vehicle's charging socket.

[0030] The insertion of the charging adapter into a vehicle's charging socket can now be detected by an integrated EV detection feature. This feature monitors the voltage signal on the CP and PP signal lines. If these signals are within an expected range, the connection to the vehicle is considered complete.

[0031] If the connection of the signal lines CP and PP to the charging station has been optionally disconnected, these will be reconnected after the vehicle is plugged in to enable communication between the charging station and the vehicle.

[0032] Before charging begins, the vehicle locks the charging adapter to prevent it from being unplugged during the process. This vehicle-side locking mechanism is only available for adapters connected to the vehicle. This prevents the formation of an arc.

[0033] After charging, the adapter can be unlocked, for example by pressing a release button. A specific time period can then be observed, or identification can be used to determine that there is no longer a connection to a vehicle. The adapter then returns to the locked position.

[0034] The connection to the charging plug is also released if it was previously fixed. Afterwards, the adapter can also be disconnected from the charging plug.

[0035] Preferably, the plug adapter also features temperature monitoring. For this purpose, the plug adapter includes temperature detection and corresponding monitoring. Using temperature detection, the plug adapter measures the temperature inside the adapter during charging. If this temperature exceeds a predetermined value, the CP signal line is interrupted to stop the charging process.

[0036] After such an interruption of the charging process, it can be restarted if the predetermined temperature is undershot, or, as described above, the plug adapter must first be disconnected from the vehicle and then plugged in.

[0037] The plug adapter includes a power supply to provide electrical energy to its individual components. Preferably, the electrical voltage is taken from the load current lines. Alternatively, the power supply can also be drawn from the pilot lines.

[0038] The electrical energy for the power supply can be drawn from an energy storage device (capacitor, battery, etc.). This energy storage device is then preferably charged from the load current lines DC+ / DC- or parasitically from the signal lines CP / PP whenever voltage is present there. Alternatively, batteries can be replaced or charged via a separate connection (e.g., via USB).

[0039] The voltage measurements in the plug adapter are preferably designed with isolation, which means that the electronic components for measuring the voltage of the potentials to be measured are galvanically isolated from the other potentials of the plug adapter and an associated non-touch-protected circuit.

[0040] Further features can be seen in the attached drawings. They show: Fig. 1: Schematic circuit diagram of a plug adapter according to the invention Fig. 2: Plug adapter with locking hook in locked position Fig. 3: Plug adapter with locking hook in the unlocked state Fig. 4: Flowchart of the plug-in adapter process (Part 1, is shown in Fig. 5 continued) Fig. 5: Flowchart of a plug-in procedure for the adapter (Part 2, continuation of Fig. 4) Fig. 6: Flowchart of a charging process with temperature monitoring

[0041] Fig. Figure 1 shows a schematic circuit diagram of a plug adapter according to the invention for carrying out the method already described. This plug adapter can be arranged between a NACS charging plug 9 and a vehicle. For this purpose, the plug adapter has two pluggable connections: on one side a pluggable connector to the NACS charging plug 9 and on the other side a pluggable connector to the vehicle. Fig. 1 The vehicle-side pluggable connector is located on the opposite side of the NACS charging plug 9.

[0042] Accordingly, the plug adapter has an infrastructure side, by means of which it can be plugged into the NACS charging plug 9, and a vehicle side, by means of which it can be inserted into the charging socket on the vehicle side.

[0043] The plug adapter can assume both a locked and an unlocked state. Fig. Figure 1 shows the plug adapter in the locked position, which can be identified by the fact that the locking hook 8 is shown in a non-angled position. In the locked position, the plug adapter cannot be connected to or disconnected from the vehicle. In the unlocked position, the plug adapter can be inserted into or unplugged from the vehicle's charging socket.

[0044] The movable locking hook 8 is preferably pivotally mounted and can be moved from a non-angled state to an angled state, which corresponds to the unlocked state. The movement of the locking hook 8 can be controlled by a locking mechanism 2 in the plug adapter. The locking mechanism controls the locking hook 8 and can bring about one of the two states of the plug adapter.

[0045] The plug adapter carries DC+ and DC- load current lines, which are required for charging the vehicle, as well as communication lines and signal lines (CP, PP, PE) from the infrastructure side to the vehicle side, with switching contacts 10 provided in the DC+ and DC- load current lines to interrupt the DC+ and DC- load current lines and thus interrupt the charging process.

[0046] Furthermore, the plug adapter includes a power supply 1 for the other electrical or electronic devices connected to the adapter. This voltage can be taken from the load current lines DC+ and DC- or from the signal lines CP, PP, and PE. Optionally, power supply 1 includes a voltage transformer and can supply devices 2, 3, 4, 5, 6, and 7.

[0047] The plug adapter includes an identification code 3 to evaluate communication via the CP signal line. This is a security feature and will be described in more detail later in the procedure.

[0048] Monitoring (4) is also provided to evaluate the specified charging parameters transmitted via the PP signal line. This is also a safety feature and will be described in more detail later in the procedure.

[0049] The plug adapter includes a voltage measurement module 5 to detect the voltage value on the DC+ and DC- load current lines and to enable further functions within the plug adapter. The voltage measurement module can transmit the measured values ​​to a detection module 6. This detection module determines whether the plug adapter is connected to a NACS charging connector 9 or not.

[0050] Finally, the plug adapter includes a relay driver 7, which can switch the switching contacts 10.

[0051] The movement of the locking hook 8 is in the Fig. 2 and Fig. 3 shown. This shows the Fig. 2. A plug adapter which is connected to a NACS charging plug 9 and is in a locked position. The locking hook 8 is not angled and thus prevents the plug adapter from being plugged in or unplugged from the vehicle.

[0052] The Fig. Figure 3, on the other hand, shows a plug adapter connected to a NACS charging connector 9, which is in an unlocked state. The locking hook 8 is angled, thus allowing the plug adapter to be connected to or disconnected from the vehicle.

[0053] The locking hook 8 is designed to engage in a projection in the charging socket of a vehicle when locked.

[0054] Fig. Figure 4 shows the sequence of a method according to the invention. This starts from the initial state in which the plug adapter is not connected on either side (i.e., on the socket side as well as the vehicle side) and the NACS charging plug 9 is not connected to a vehicle.

[0055] First, a customer plugs the adapter into the NACS charging connector 9, thus establishing a connection between the adapter and the NACS charging connector 9, as is also the case in the Fig. 2 and Fig. 3 is shown.

[0056] Depending on the charging infrastructure, it is now preferably necessary for the customer to authorize themselves at the charging station so that the station can initiate the charging process and generate a corresponding invoice for the user. There are many disclosures regarding state-of-the-art authorization methods.

[0057] The plug adapter now checks the connection between the plug adapter and the NACS charging plug 9 and initiates a detection 6 that the plug adapter has been plugged into a charging plug.

[0058] For testing purposes, a high-voltage detection (HV voltage measurement) is performed in the plug adapter. For this, a voltage measurement device (8) is used to determine whether a charging voltage is present on the DC+ and DC- load current lines. The detection device (6) evaluates the measured charging voltage. If this voltage is present and, if applicable, within the expected range for the charging voltage value, the detection is successful.

[0059] If detection is unsuccessful, the plug adapter remains locked and optionally disconnects at least the DC+ and DC- load current lines within the plug adapter via the switching contacts 10, preventing any voltage from reaching the infrastructure side of the plug adapter. This ensures protection against accidental contact for the user, i.e., the customer. The plug adapter is now in a safe state, but a charging process cannot be initiated in this safe state. Optionally, the safe state can be indicated visually or audibly.

[0060] Furthermore, CP detection is implemented in the plug adapter. This serves to identify the actual charging process; charging processes according to ISO 15118 or IEC 61851 as well as DIN EN 70121 are possible. In addition to the DC+ and DC- load current lines, the plug adapter includes communication lines, namely the "control pilot" (CP) and the "proximity pilot" (PP). A grounding line (PE) is also present. The CP detection is also linked to the locking mechanism.

[0061] For CP detection, the plug adapter includes an identification module 3, which is connected to the CP signal line and the PE ground line and can measure the voltage on the CP signal line. If this voltage is within an expected range, detection is successful.

[0062] If detection is unsuccessful, the plug adapter remains locked and optionally disconnects at least the DC+ and DC- load current lines via the switching contacts 10 in the plug adapter, so that no voltage reaches the infrastructure side of the plug adapter. This ensures protection against contact for the person operating the adapter. The plug adapter is now in a safe state, but a charging process cannot be initiated in this safe state. Optionally, the safe state can be indicated by visual or audible means.

[0063] Optionally, a time window is now waited for, which is required for communication according to ISO 15118, in order to end the communication on the CP signal line.

[0064] An AC charging process according to IEC 61851 is now simulated in the plug adapter. For this purpose, the status of the plug adapter and the position of the locking hook 8 are checked using a monitoring device 4, and communication is simulated using the identification device 3. The voltage type on the load current lines DC+ and DC- can also be detected using a detection device: AC or DC. If AC voltage is detected, the test fails because the plug adapter is only intended for DC power supplies. Subsequently, a DC charging process according to ISO 15118 or DIN EN 70121 can be simulated in the plug adapter in a similar manner.

[0065] If all functions of the test fall within the expected value ranges, the test is successful.

[0066] If the test fails, the plug adapter remains locked and optionally disconnects at least the DC+ and DC- load current lines within the plug adapter via the switching contacts 10, thus preventing any voltage from reaching the infrastructure side of the plug adapter. This ensures protection against accidental contact for the user. The plug adapter is now in a safe state, although a charging process cannot be initiated in this safe state. Optionally, the safe state can be indicated by visual or audible signals.

[0067] If the detection and testing are successful, the connection between the charging plug and the plug adapter can optionally be fixed, e.g. by a locking mechanism provided by the plug adapter.

[0068] Now, the connection of the signal lines CP and PP to the charging station is separated by a separating agent in the plug adapter in order to protect and insulate them during the plugging process with the vehicle.

[0069] The plug adapter is then moved into the unlocked state by means of the locking mechanism 2. This allows the locking hook 8 to move into a position that enables the plug adapter to be inserted into the charging socket of a vehicle.

[0070] The insertion of the plug adapter into a vehicle's charging socket can now be detected by an integrated EV detection feature in the plug adapter. Monitoring module 4 checks the voltage signal on signal line PP. If this signal is within an expected range, the connection to the vehicle is considered complete.

[0071] The CP and PP signal lines are now reconnected after the charging station is plugged into the vehicle to enable communication between the charging station and the vehicle. All voltage and signal lines are now connected via the adapter from the charging plug to the vehicle.

[0072] After the connection process, the adapter is returned to its locked position to prevent it from being disconnected from the vehicle during charging. This prevents the formation of an arc if the adapter is disconnected while charging.

[0073] After charging, the adapter can be unlocked, for example by pressing a release button. A specific time period can then be observed, or identification code 4 can be used to determine that there is no longer a connection to a vehicle. The adapter then returns to the locked position.

[0074] The connection to the charging plug is also disconnected. Afterwards, the adapter can also be disconnected from the charging plug.

[0075] The plug adapter can also feature temperature monitoring. A corresponding procedure for charging with temperature monitoring is described in Fig. 6 shown.

[0076] The plug adapter includes temperature detection and monitoring. During charging, the adapter measures its internal temperature. If this temperature exceeds a predefined threshold, the CP signal line is interrupted, thus halting the charging process. It is recommended that the temperature detection be located on at least one contact of the DC+ and DC- load current lines.

[0077] After such an interruption of the charging process, it can be restarted if the predetermined temperature is undershot, or, as described previously, the plug adapter must first be disconnected from the vehicle and then reconnected. In this case, the plug adapter is disconnected, as described earlier, by pressing the release button.

[0078] The present invention is not limited to the aforementioned features. Rather, further embodiments are conceivable. For example, the voltage measurement, the detection, and the relay driver for the switching contacts could be integrated into a single component. Likewise, the latching hook could be designed as a shutter or locking mechanism. REFERENCE MARK LIST 1 Power supply 2 Locking 3 Identification 4 Monitoring 5 Voltage measurement 6 Recognition 7 relay drivers 8 locking hooks 9 NACS charging plugs 10 switching contacts CP signal line CP (“control pilot”) PP signal cable PP (“proximity pilot”) PE earthing conductor PE (“protection earth”) DC+, DC load current lines QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 2023 / 205304 A1

[0006]

Claims

[1] Method for the safe operation of a NACS plug adapter, the plug adapter can assume a locked and an unlocked state, wherein the plug adapter is positioned between a NACS charging plug (9) and a vehicle, characterized by , that the plug adapter initially assumes the locked state and therefore cannot be coupled to a vehicle, that the plug adapter is connected to the charging plug (9) in the locked position, that the connection between plug adapter and charging plug (9) is checked and detected and upon successful testing and detection (6) of the connection between plug adapter and charging plug (9) the plug adapter is moved into the unlocked state to enable a connection of the plug adapter to the vehicle and, after successful connection, to enable a vehicle-side locking to prevent a disconnection of the connection between plug adapter and vehicle. [2] Method according to claim 1, characterized by , that the connection between plug adapter and charging plug (9) is tested via an HV test in the plug adapter. [3] Method according to claim 1 or 2, characterized by , that the detection of the connection between plug adapter and charging plug (9) includes CP detection on a signal line CP and / or PP detection on a signal line PP in the plug adapter. [4] Method according to any one of claims 1 to 3, characterized by, that the detection of the connection between plug adapter and charging plug (9) is carried out via a simulation of an AC charging process and / or DC charging process. [5] Method according to any one of claims 1 to 4, characterized by , that if an error occurs during the testing or detection of the connection between the plug adapter and the charging plug (9), the plug adapter remains in the locked state to prevent the plug adapter from being connected to the vehicle. [6] Method according to any one of claims 1 to 5, characterized by , that after the connection between plug adapter and charging plug (9) has been detected and tested, if no fault occurs, the plug adapter is moved into the unlocked state to allow the plug adapter to be connected to the vehicle. [7] Method according to any one of claims 1 to 6, characterized by , that an EV detection system can be used to determine whether the plug adapter is connected to a vehicle. [8] Method according to any one of claims 1 to 7, characterized by , that a charging process is enabled after successful detection and verification of the connection between plug adapter and charging plug (9) and successful EV detection. [9] Method according to any one of claims 1 to 8, characterized by , that the temperature in the plug adapter is monitored by means of a temperature monitoring system and, in the event of an overtemperature detected by a temperature sensor, a charging process is aborted by interrupting the CP and / or PP and a further charging process is prevented. [10] Method according to any one of claims 1 to 9, characterized by , that the plug adapter is moved into the unlocked state when a release button is pressed and no charging process is taking place. [11] Plug adapter for carrying out the method according to any one of claims 1 to 10, wherein the plug adapter has a connection side for electrically connecting the plug adapter to a NACS charging plug (9) and a connection side for electrically connecting the plug adapter to a vehicle, characterized by , that the plug adapter has a power supply and a locking hook (8) which makes the plug adapter capable of being placed in a locked and an unlocked state, wherein the locking hook (8) is controllable via a locking mechanism (2) in the plug adapter. [12] Plug adapter according to claim 11, characterized by , that includes identification (3) of the plug adapter to a vehicle and / or monitoring (4) of the locking hook (8). [13] Plug adapter according to claim 11 or 12, characterized by, that a voltage measurement (5), a detection (6) of the electrical voltage and / or a relay driver for switching contacts in the load current lines (DC+, DC-) is included in the plug adapter. [14] Plug adapter according to claim 13, characterized by , that a detected fault leads to the disconnection of the signal lines (CP, PP) and / or the load current lines (DC+, DC-) through the switching contacts (10) in the plug adapter.

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