Vehicle charging system for an electric vehicle with arc flash detection

Abstract

A vehicle charging system (10) for an electric vehicle (14) comprises a housing (102) with a DC charging port (108) held by the housing in an internal cavity (134), with a connection end for connecting to the charging device (100) and connected to a power cable (105). The vehicle charging system includes a charge controller (30) for controlling the vehicle charging along the DC charging port. The vehicle charging system includes an arc sensor (34) in the internal cavity, configured to detect an arcing event at the connection end of the DC charging port. The arc sensor includes a light detector (180) with a multimodal diversity detector, configured in a first mode to detect light from the arcing event and in a second mode to detect an arcing noise signature from the arcing event.The arc flash sensor is operationally coupled to the charge controller to control the vehicle charging when an arc flash event is detected.

Description

[0001] This application claims priority over U.S. Application No. 63 / 724,578, filed on November 25, 2024, entitled "Vehicle Charging System for an Electric Vehicle with Arc Detection," the subject matter of which is hereby incorporated in its entirety by reference.

[0002] The subject matter of the present application relates generally to vehicle charging systems.

[0003] Electric vehicles (EVs) and hybrid electric vehicles (HEVs) include battery systems to power the vehicles. These battery systems are charged by a vehicle charging system. For example, a charging plug connected to a power source is plugged into a charging inlet assembly on the vehicle to charge the battery. However, existing vehicle charging systems are not without their drawbacks. For instance, the temperature of the connectors can rise during charging, potentially damaging the charging components. In some cases, arcing can occur between the charging components, which can damage both the charging plug and the charging inlet assembly.

[0004] There is still a need for arc flash detection for an electric vehicle charging system.

[0005] In one embodiment, a vehicle charging system for an electric vehicle is provided, comprising a housing with a connection end for connecting to a charging device for the electric vehicle. The housing includes an inner cavity. The vehicle charging system includes a DC charging connector, which is held by the housing within the inner cavity. The DC charging connector includes a connection end for connecting to the charging device. The DC charging connector is connected to a power cable. The vehicle charging system includes a charge controller for controlling the vehicle charging along the DC charging connector. The vehicle charging system includes an arc fault sensor in the inner cavity, configured to detect an arc fault at the connection end of the DC charging connector. The arc fault sensor includes a light detector.The light detector is a multimodal diversity detector configured in one mode to detect light from the arcing event, and in a second mode to detect an arcing noise signature from the arcing event. The arcing sensor is operationally coupled to the charge controller to control the vehicle's charging when the arcing event is detected.

[0006] The invention is described by way of example with reference to the attached figures, wherein Fig. 1 is a schematic representation of a vehicle charging system according to an exemplary embodiment. Fig. 2 is a front side of a charging device according to an exemplary embodiment. Fig. 3 is a rear side of the charging device according to an exemplary embodiment. Fig. Figure 4 is a perspective view of the charge controller according to an exemplary embodiment. Fig. Figure 5 is a cross-sectional view of the charging device according to an exemplary embodiment, showing a second charging device coupled to the charging device. Fig. Figure 6 is a cross-sectional view of the charging device according to an exemplary embodiment, showing the second charging device coupled to the charging device.

[0007] Fig. Figure 1 is a schematic view of a vehicle charging system 10 according to an exemplary embodiment. The vehicle charging system 10 is used to charge a battery system 12 of a vehicle 14, for example, an electric vehicle or a hybrid electric vehicle. The vehicle charging system 10 comprises a first charging device 20 and a second charging device 40. The first and second charging devices 20 and 40 are coupled to each other to charge the battery system 12 of the vehicle 14. In an exemplary embodiment, the first charging device 20 is coupled to the vehicle 14, and the second charging device 40 is coupled to a power supply 16, which is used to charge the battery system 12 of the vehicle 14.For example, the first charging device 20 can be a charging inlet assembly 22 mounted on the vehicle 14, and the second charging device 40 can be a charging plug 42 which may be provided at a charging station or coupled to the building wiring of the house or building in which the vehicle 14 is parked.

[0008] The first charging device 20 comprises a housing 24 containing a plurality of charging ports 26. The charging ports 26 can be DC charging ports and / or AC charging ports.

[0009] The first charging device 20 includes a charge controller 30, which can be used to control the vehicle's charging process. For example, the charge controller 30 can control the power supply along the charging terminals 26. The charge controller 30 can communicate with the second charging device 40, for example, to control the second charging device 40. For example, the charge controller 30 can cause the second charging device 40 to switch on the power supply, switch off the power supply, increase the power supply, and / or decrease the power supply.

[0010] In an exemplary embodiment, the first charging device 20 comprises a temperature sensor 32 which is operationally coupled to the charge controller 30 to monitor the temperature of the charging terminals 26. Charging of the vehicle can be controlled based on the temperature readings of the temperature sensor 32. The temperature sensor 32 can be used for arc fault detection, for example, by monitoring a temperature increase or a temperature above a threshold temperature, which may be higher than a normal operating temperature range.

[0011] In an exemplary embodiment, the first charging device 20 comprises an arc flash sensor 34, which is operationally coupled to the charge controller 30 to detect an arc flash event within the first charging device 20, for example, at the charging port 26. The arc flash sensor 34 is operationally coupled to the charge controller 30 to control the vehicle charging when the arc flash event is detected. For example, when the arc flash event is detected, the charge controller immediately cuts off the power supply to stop the charging process and extinguish the arc flash. In an exemplary embodiment, the arc flash sensor 34 may include a light detector, for example, a photodiode, to detect light from the arc flash event.In an exemplary embodiment, the arc sensor 34 can be a diversity detector configured to detect the arc event using multiple detection methods, for example, by operating in different modes or detecting different frequency ranges. For example, the arc sensor 34 can be a multimodal diversity detector configured in a first mode to detect light from the arc event and in a second mode to detect an arc noise signature from the arc event. The arc sensor 34 can detect light in the optical frequency spectrum in the first mode and electromagnetic waves in the radio frequency spectrum in the second mode. For example, the arc sensor 34 can detect optical waves in the first mode and electrical waves in the second mode.The arc flash sensor 34 can operate simultaneously in both modes. The arc flash sensor 34 can be configured to detect the arc flash event in mode 1 with a direct line of sight to the event, and it can be configured to detect the arc flash event in mode 2 without a direct line of sight to the event.

[0012] The second charging device 40 comprises a housing 44 containing a plurality of charging ports 46. The charging ports 46 are configured to connect to the charging ports 26. In various embodiments, the charging ports 46 are socket ports and the charging ports 26 are pin ports; however, in alternative embodiments, other types of ports may also be used. The charging ports 46 can be DC charging ports and / or AC charging ports.

[0013] The second charging device 40 includes a charge controller 50, which can be used to control the vehicle charging. For example, the charge controller 50 can control the power supply along the charging terminals 46. The charge controller 50 can communicate with the first charging device 20. The charge controller 50 can switch the power supply on, off, increase, and / or decrease the power supply. The charge controller 50 can control the voltage and / or current supplied by the second charging device 40.

[0014] In an exemplary embodiment, the second charging device 40 includes a temperature sensor 52, which is operationally coupled to the charge controller 50 to monitor the temperature of the charging terminals 46. Vehicle charging can be controlled based on the temperature readings from the temperature sensor 52. The temperature sensor 52 can be used for arc fault detection, for example, by monitoring a temperature increase or a temperature above a threshold temperature, which may be higher than a normal operating temperature range.

[0015] In an exemplary embodiment, the second charging device 40 comprises an arc flash sensor 54, which is operationally coupled to the charge controller 50 to detect an arc flash event at the plug interface, for example, at the charging port 46. The arc flash sensor 54 is operationally coupled to the charge controller 50 to control the vehicle charging when the arc flash event is detected. For example, when the arc flash event is detected, the charge controller immediately cuts off the power supply to stop the charging process and extinguish the arc flash. In an exemplary embodiment, the arc flash sensor 54 can include a light detector, for example, a photodiode, to detect light from the arc flash event.In an exemplary embodiment, the arc sensor 54 can be a diversity detector configured to detect the arc event using multiple detection methods, for example, by operating in different modes or by detecting different frequency ranges. For example, the arc sensor 54 can be a multimodal diversity detector configured in a first mode to detect light from the arc event and in a second mode to detect an arc noise signature from the arc event. The arc sensor 54 can detect light in the optical frequency spectrum in the first mode and electromagnetic waves in the radio frequency spectrum in the second mode. For example, the arc sensor 54 can detect optical waves in the first mode and electrical waves in the second mode.The arc flash sensor 54 can operate simultaneously in both modes. The arc flash sensor 54 can be configured to detect arc flash events in mode 1 with a direct line of sight to the event, and it can be configured to detect arc flash events in mode 2 without a direct line of sight to the event.

[0016] Fig. 2 is a front side of a charging device 100 according to an exemplary embodiment. Fig. Figure 3 is a rear side of the charging device 100 according to an exemplary embodiment. In the illustrated embodiment, the charging device 100 is a charging inlet arrangement and may hereinafter be referred to as the charging inlet arrangement 100. The charging inlet arrangement 100 is configured so that it can be connected to a complementary charging device (not shown), such as a charging plug or a plug-in charger.

[0017] The charging inlet assembly 100 defines a power connector 101 configured to connect electrically to the charging plug for charging a vehicle's battery system, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). In one exemplary embodiment, the charging inlet assembly 100 is configured to connect to a DC fast-charging plug, such as the SAE combo CCS charging plug or the NACS charging plug, in addition to AC charging plugs, such as the SAE J1772 charging plug. In various embodiments, the charging inlet assembly 100 has a CCS1 (5-pin) AC configuration. In other various embodiments, the charging inlet assembly 100 may have a CCS2 (7-pin) AC configuration. Alternative embodiments may use other standard inlet configurations.

[0018] The charging inlet assembly 100 comprises a housing 102 configured for mounting in the bracket in the vehicle. The housing 102 forms part of the power connector 101 for connection to the charging plug. A rear cover 103 (in Fig. 2 shown, in Fig. (3, however, removed to illustrate the components of the charging inlet assembly 100) is connected to a rear of the housing 102 to close the housing 102 and the internal components of the charging inlet assembly 100. The rear cover 103 can be sealed to the housing 102 to prevent moisture and dirt from entering the interior of the housing 102. In an exemplary embodiment, the power connector 101 defines a DC charging section 104 and an AC charging section 106. The charging sections 104 and 106 can form recesses or openings that accommodate a plug of the charging connector. The charging inlet assembly 100 includes a plurality of charging ports 107 for connection to the charging connector. Power cables 105 are electrically connected to the charging ports 107 and routed within the vehicle, for example, to the battery.

[0019] The DC charging section 104 is configured to be connected to a DC charging plug or a DC section of the charging plug. The DC charging section can be used for fast charging. In an exemplary embodiment, the charging ports 107 of the charging inlet assembly 100 comprise DC charging ports 108 on the DC charging section 104, for example, a pair of DC charging ports 108. The DC charging ports 108 are configured to be electrically connected to the DC charging plug. The charging inlet assembly 100 comprises DC cables 109 ( Fig. 2) which are electrically connected to the DC charging terminals 108. The DC cables 109 can be directly connected to the DC charging terminals 108, for example by crimping or welding them. In other embodiments, the DC cables 109 can be electrically connected to the DC charging terminals 108 via a detachable interface, for example via connectors that are connected to the housing 102 at the rear.

[0020] The AC charging section 106 is configured to be connected to an AC charging plug or an AC section of the charging plug. In an exemplary embodiment, the charging ports 107 of the charging inlet assembly 100 comprise AC terminals 110 on the AC charging section 106, for example, a pair of AC terminals 110. The charging ports 107 of the charging inlet assembly 100 comprise a proximity terminal 112 on the AC charging section 106. The charging ports 107 of the charging inlet assembly 100 comprise a grounding terminal 114 on the AC charging section 106. The charging ports 107 of the charging inlet assembly 100 comprise a communication terminal 116 on the AC charging section 106. The AC terminals 110, the proximity terminal 112, the grounding terminal 114, and the communication terminal 116 are configured to be electrically connected to the AC charging plug.

[0021] The charging inlet assembly 100 includes AC cables 111 ( Fig. 2) which are electrically connected to the corresponding AC terminals 110, 112, 114, 116. The AC cables 111 can be directly connected to the AC terminals 110, 112, 114, 116, for example by crimping or welding. In other embodiments, the AC cables 111 can be electrically connected to the AC terminals 110, 112, 114, 116 via a detachable interface, for example via connectors that are connected to the rear of the housing 102.

[0022] Cables 109 and 111 extend from the charging inlet assembly 100 to another vehicle component, such as the vehicle's battery system. These cables transmit current, for example, to the vehicle's battery. The DC cables 109 can transmit high voltage for charging the battery, and the AC cables 111 can transmit low voltage for charging the battery. Optionally, one or more of the cables 111 can be electrically connected to a battery control unit (not shown) of the battery system, for example, to transmit data between the charging inlet assembly 100 and the battery system, such as data related to the charging process. For example, cable 111 can transmit data about the start / stop of the charging process, the operating temperature of the power terminals 108 and / or 110, or other charging data.Cable 111 can send a proximity signal to the battery system indicating when the charger is connected to the power terminal 101 of the charging inlet assembly 100.

[0023] The charging inlet assembly 100 includes a mounting flange 120 ( Fig. 1), which is connected to the housing 102. The mounting flange 120 serves to connect the charging inlet assembly 100 to the vehicle. The mounting flange 120 includes mounting tabs 122 with openings 124 that accommodate fasteners (not shown) used to attach the charging inlet assembly 100 to the vehicle. Other types of fasteners may also be used to attach the charging inlet assembly 100 to the vehicle. The mounting flange 120 may include a gasket to keep the charging inlet assembly 100 sealed to the vehicle.

[0024] In an exemplary embodiment, the charging inlet arrangement 100 comprises a connection cover 126 ( Fig. 2) on a front 130 of the housing 102. The terminal cover 126 is pivotally connected to the mounting flange 120 and / or the housing 102. The terminal cover 126 serves to cover parts of the housing 102, such as the power connector 101. The terminal cover 126 can be used to cover the DC charging connectors 108 and / or the AC connectors 110, which are located in corresponding connection channels 128 in the housing 102.

[0025] The rear cover 103 is provided on a rear side 132 of the housing 102 to close off access to a rear chamber 133 on the rear side 132 of the housing 102. The rear cover 103 can be attached or locked to the main part of the housing 102, for example, using clips or latches. In alternative embodiments, other types of fasteners, such as closures, can also be used. A circumferential seal can be provided between the rear cover 103 and the housing 102.

[0026] In an exemplary embodiment, the housing 102 of the charging inlet assembly 100 comprises an inner cavity 134 that accommodates the components of the charging inlet assembly 100. The rear side 133 of the inner cavity 134 is located at the rear of the inner cavity 134. The inner cavity 134 includes the connection channels 128, which accommodate the corresponding charging connectors 107. The connection channels 128 may be separated from each other and from other components by walls of the housing 102. The inner cavity 134 includes a front chamber 138 at the front, which accommodates the charging connector.

[0027] In an exemplary embodiment, the charging inlet arrangement 100 includes a charge controller 140 for controlling the charging of the vehicle via the charging inlet arrangement 100. The charge controller 140 can be located in the internal cavity 134, for example, in the rear 133. The charge controller 140 can be communicatively coupled with the other charging device, for example, the charging plug or connector, to control the charging. For example, the charge controller 140 can be connected to the charging plug via one or more of the terminals 107. The charge controller 140 can switch the power supply on, off, increase, and / or decrease it. The charge controller 140 can be located remotely from the housing 102, for example, on the battery control module of the vehicle charging system.

[0028] With further reference to Fig. Figure 4, which shows a perspective view of the charge controller 140 according to an exemplary embodiment, comprises a printed circuit board 142, a control unit 144, and various other components and circuits for controlling the operation of the charging inlet arrangement 100. The control unit 144 can be a processor or a microcontroller. The control unit 144 can include a multi-pin connector connected to the printed circuit board 142.

[0029] In an exemplary embodiment, the control unit comprises one or more sensors 150, which are used to control the charging process. The sensors 150 are used to detect the operating characteristics of the components or the charging process in order to control the charging. The sensors 150 are connected to the charge controller 140, for example via a wire or a connector to the circuit board 142.

[0030] In various embodiments, the sensors 150 include temperature sensors 152. The temperature sensors 152 monitor the operating temperatures of the DC charging ports 108. The charging process can be controlled based on the operating temperatures of the DC charging ports 108. For example, if the temperature rises or approaches a permissible operating temperature, the power supply can be reduced. For example, the voltage or current can be reduced. The charging process can be stopped if the operating temperature of the DC charging ports 108 exceeds a threshold temperature. The temperature sensor 152 can be used for arc fault detection, for example, by monitoring a temperature rise or a temperature exceeding a threshold temperature, which may be higher than a normal operating temperature range.

[0031] In various embodiments, the sensors comprise 150 arc sensors 160. The arc sensors 160 detect an arc flash within the charging inlet assembly 100, for example, at the connection ends of the DC charging terminals 108. The charging process can be controlled based on the detection of the arc flash. For example, if the arc flash is detected, the charging process is stopped. The current and voltage from the charging connector are immediately interrupted to prevent damage to the components or the vehicle.

[0032] In an exemplary embodiment, the arc sensor 160 can include a light detector, for example, a photodiode, to detect light from the arc event. In another exemplary embodiment, the arc sensor 160 can be a diversity detector configured to detect the arc event using multiple detection methods, for example, by operating in different modes or by detecting different frequency ranges. For example, the arc sensor 160 can be a multimodal diversity detector configured in a first mode to detect light from the arc event and in a second mode to detect an arc noise signature from the arc event. The arc sensor 160 can detect light in the optical frequency spectrum in the first mode and electromagnetic waves in the radio frequency spectrum in the second mode.For example, the arc flash sensor 160 can detect optical waves in the first mode and electrical waves in the second mode. The arc flash sensor 160 can operate in both modes simultaneously. The arc flash sensor 160 can be configured to detect the arc flash event in the first mode with a direct line of sight to the event, and it can be configured to detect the arc flash event in the second mode without a direct line of sight to the event.

[0033] Fig. Figure 5 is a cross-sectional view of the charging device 100 according to an exemplary embodiment, which shows a second charging device 60 coupled to the charging device. Fig. Figure 6 is a cross-sectional view of the charging device 100 according to an exemplary embodiment, showing the second charging device 60 coupled to the charging device. In the illustrated embodiment, the charging device 100 is the charging inlet arrangement. The second charging device 60 is a charging plug, for example, a plug-in power supply.

[0034] The charging ports 107 are shown in the connection channels 128 of the housing 102. The charging ports 107 are connected to the charging ports 62 of the charging plug 60. In the illustrated embodiment, the charging ports 107 are pin connectors and the charging ports 62 are socket connectors with spring contacts 64 in the sockets, which are configured to electrically connect the charging ports 62 and the charging ports 107. The spring contacts 64 form a compliant, separable interface. The spring contacts 64 can be prone to failure due to overheating, and such failure can lead to an arcing event. The temperature sensors 152 monitor the temperature of the charging ports 107. The arc sensors 160 monitor the plug area for arcing events, for example, at the connection ends 66 of the charging ports 62 or at the connection ends of the charging ports 107.

[0035] The charging plug 107 comprises a mating pin 200 at a connection end 210 of the charging plug 107 and a cable connector 202 on a rear side 212 of the charging plug 107. The charging plug 107 extends along a longitudinal axis. The mating pin 200 is configured to connect to the spring contact 64 of the charging port 62 of the charging plug 60. The cable connector 202 is configured to connect electrically to the power cable 109. In various embodiments, the cable connector 202 is configured to connect to the power cable 109 by crimping. In other embodiments, the cable connector 202 is connected to the power cable 109 by other methods, for example, by welding to a weld tab on the rear side of the charging port 107. The cable 109 can extend from the charging port 107 perpendicular to the longitudinal axis.Alternatively, the cable 109 can extend from the charging port 107 parallel to the longitudinal axis.

[0036] In one exemplary embodiment, the temperature sensor 152 is coupled to the charging port 107 at its rear, for example, at the cable connector 202. The charging port 107 is both electrically and thermally conductive. When the mating pin 200 heats up during charging, the entire body of the charging port 107 also heats up. This temperature increase is detected by the temperature sensor 152. In various embodiments, the temperature sensor 152 is a thermistor. The temperature sensor 152 can also include a resistance temperature detector.

[0037] The arc sensor 160 detects an arcing event within the charging inlet assembly 100, for example, at the connection ends 210. In various embodiments, the arc sensor 160 monitors the light generated by the arcing event to detect the arcing event. In other embodiments, the arc sensor 160 monitors an arcing noise signature to detect the arcing event. In one exemplary embodiment, the arc sensor 160 is a multimodal diversity detector configured to detect the arcing event using multiple detection methods by operating in different modes. For example, in a first mode, the arc sensor 160 detects light from the arcing event, and in a second mode, the arc sensor 160 detects an arcing noise signature from the arcing event.

[0038] In an exemplary embodiment, the arc sensor 160 comprises a light detector 180, for example a photodiode, to detect light from the arc event (in the first mode). For example, the arc event generates light, for example in the optical frequency range. The light from the electric arc can be in a predetermined range, for example in the infrared frequency range and / or in the visible frequency range and / or in the ultraviolet frequency range. The light detector 180 is positioned to visibly monitor the inner cavity 134, for example in the connection channel 128, in order to detect the arc event near the plug interface between the charging terminals 107, 62. The light detector 180 can be positioned in the inner cavity 134, for example in the connection channel 128.In other embodiments, the light detector 180 is located in the housing 102, for example at a window 170 to the inner cavity 134, in order to monitor the plug interface for an arc flash event through the window 170. The window 170 is transparent, for example made of transparent plastic, to allow the detection of the arc flash event through the window 170. The light detector 180 is isolated from the charging terminals 107, 62 by the window 170. The window 170 can, for example, be made of a dielectric material. The light detector 180 detects light in the optical frequency spectrum. The light detector 180 can, for example, detect optical waves. The light detector 180 is configured to detect the arc flash event with a direct line of sight to the arc flash event.

[0039] In an exemplary embodiment, an optical fiber 182 extends between the connection channel 128 and the light detector 180. The optical fiber 182 can be an optical fiber. The optical fiber 182 extends between a first end 184 and a second end 186. The first end 184 is coupled to the light detector 180. The second end 186 is positioned near the connection end of the charging port 107. Light from the arc event is transmitted from the second end 186 to the first end 184 to be detected by the light detector 180. In an exemplary embodiment, a UV-sensitive coating 188 can be applied to the housing 102 near the connection end of the charging port 107, for example, within the connection channel 128.The UV-sensitive coating 188 is activated during the arc event to amplify the light generated during the arc event, thus enabling faster and / or more reliable monitoring by the light detector 180.

[0040] The arc discharge at the connector interface occurs in air. When excited by an arc, the nitrogen and oxygen in the air emit light. The two strongest emission lines for oxygen are at 430 nm and 538 nm, which are in the near-UV and deep blue regions, respectively. Since there is normally no light inside the connected connector, the light intensity detected by the light detector 180 would indicate the start of an arc discharge. The light detector 180 can detect light escaping through small gaps in the mating connector or light guided from the terminal area to the sensor via the light guide 182. The light guide 182 can pass through the housing 102 without affecting its electrical insulation properties.The detection of leaked light could be improved by coating the inner walls of the connector with a UV-sensitive coating that scatters the light more effectively towards the light detector 180.

[0041] In an exemplary embodiment, the arc sensor 160 monitors an arc noise signature to detect the arc event. For example, the arc event generates arc noise, such as in the high-frequency range as a consequence of the arc energy. The characteristic noise signature of the electric arc can lie in a predetermined range, for example, between 1 kHz and 100 GHz. The characteristic noise signature of the electric arc can lie in a more specific range, for example, between 100 and 500 kHz. The arc sensor 160 detects the stochastic energy or noise signature generated by the electric arc. In an exemplary embodiment, the arc sensor 160 can monitor an electrical circuit of the charging inlet assembly 100 to detect the arc noise signature on the electrical circuit corresponding to the arc event.The electrical circuit can be the circuit, for example along the charging terminals 107 and / or the power cables 109. The electrical circuit can be a circuit of the charge controller 140, for example a circuit on the circuit board 142 (. Fig. 3) The arc sensor 160 can monitor a spectrogram of a signal on the electrical circuit to detect the arc noise signature. The arc sensor 160 can monitor the electrical circuit for an increase in amplitude that indicates an arc. The arc sensor 160 is configured to detect the arc event (in the second mode) without a direct line of sight to the arc, for example, by detecting the noise signature energy generated by the electric arc.

[0042] The electrical conduction in an electric arc is a stochastic process that generates a characteristic noise signature, for example, between 100 and 500 kHz. In contrast, the light detector 180 of the arc sensor 160 can generate a rise detection signal during the arc event, which is linked to the light detection by the light detector 180. The arc noise signature can be easily distinguished from the light detection signal by the arc sensor 160. In various embodiments, the arc noise signature can be detected by identifying a rise in amplitude across the arc frequency range (e.g., 100–500 kHz), which indicates the start of an arc.The arc noise signature can improve arc detection, for example by eliminating false positive events, such as those caused by an increased detection signal without an arc event, and / or by eliminating false negative events, such as those caused by missed arc events due to weak light detection during an arc event.

[0043] In various embodiments, the charge controller 140 can include an arc fault circuit interrupter (ACFI) for protection against electric arcs, for example, to disconnect the charging circuit when an arc is detected. The arc sensor 160 monitors the arc noise signature in the circuit to detect the arc noise signature transmitted when an arc fault occurs. The charge controller 140 can include an internal processor in the ACFI device that distinguishes between normal operation and dangerous arcing and automatically opens the circuit to reduce the risk of system damage.

[0044] In various embodiments, the arc sensor 160 is connected to other lines or circuits to detect the arc noise signature. In other embodiments, the arc sensor 160 includes a separate, dedicated arc detection circuit that can be routed from the charging port 107 to the circuit board 142 or to another component, such as the control module. The arc sensor 160 can include a resistor-capacitor-inductor network at the charging port 107 or on the circuit board 142 to increase sensitivity to arc signatures and minimize sensitivity to normal electrical noise from the vehicle.

[0045] In one exemplary embodiment, the arc sensor 160 is electrically coupled to the electrical circuit at or near the cable connector 202 on the rear 212 of the charging port 107. The arc sensor 160 can be coupled to the cable connector 202 or to the cable 109. In various embodiments, the arc sensor 160 can include a current transformer around the power cable 109 to monitor the electrical signature along the cable 109. In other various embodiments, the arc sensor 160 can include a Hall sensor next to the cable 109 or the cable connector 202 to monitor the electrical signature along the electrical circuit. In various embodiments, the arc sensor 160 includes an induction coil to monitor the electrical signature along the electrical circuit.The induction coil can be positioned at or near the cable connector 202 or the cable 109. The induction coil can be mounted on a printed circuit board, such as the printed circuit board 142, or on another printed circuit board, such as a printed circuit board for the temperature sensor system. In various embodiments, the induction coil is wide-tuned with a capacitor. The arc sensor 160 can include insulation from the circuit, for example, from the conductors of the cable 109 or the cable connector 202, to prevent damage to the arc sensor 160. For example, the current transformers, the Hall sensor, and / or the induction coil can be electrically isolated from the conductors carrying the charging current. This electrical isolation can be achieved by suitable DC blocking capacitors to isolate the components from the charging current conductors. 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] US 63 / 724,578

[0001]

Claims

[1] A vehicle charging system (10) for an electric vehicle (14), comprising: a housing (102) with a connecting end (66) for connecting to a charging device (100) for the electric vehicle, wherein the housing comprises an inner cavity (134); a DC charging port (108) which is held by the housing in the inner cavity, wherein the DC charging port includes a connecting end for connecting to the charging device and the DC charging port is connected to a power cable (105); a charge controller (30) for controlling vehicle charging via the DC charging port; and an arc sensor (34) in the inner cavity configured to detect an arc event at the connection end of the DC charging port, wherein the arc sensor comprises a light detector (180) wherein the light detector is a multimodal diversity detector configured in a first mode to detect light from the arc event and in a second mode to detect an arc noise signature from the arc event, wherein the arc sensor is operationally coupled to the charge controller to control the vehicle charging when the arc event is detected. [2] The vehicle charging system (10) according to claim 1, wherein the light detector (180) is a photodiode. [3] The vehicle charging system (10) according to claim 1, wherein the arc sensor (34) detects light in the optical frequency spectrum in the first mode and electromagnetic waves in the radio frequency spectrum in the second mode. [4] The vehicle charging system (10) according to claim 1, wherein the arc sensor (34) detects optical waves in the first mode and electrical waves in the second mode. [5] The vehicle charging system (10) according to claim 1, wherein the arc sensor (34) is simultaneously operational in the first mode and in the second mode. [6] The vehicle charging system (10) according to claim 1, wherein the arc sensor (34) is configured to detect the arc event in the first mode with direct line of sight to the arc event, wherein the arc sensor is configured to detect the arc event in the second mode without direct line of sight to the arc event. [7] The vehicle charging system (10) according to claim 1, wherein the arc sensor (34) is located in the inner cavity (134) of the housing (102). [8] The vehicle charging system (10) according to claim 1, wherein the housing (102) comprises a window (170) to the inner cavity (134), wherein the arc sensor (34) is located in the housing at the window and is isolated from the DC charging port (108) by the window. [9] The vehicle charging system (10) according to claim 1, wherein the charge controller (30) interrupts the power supply to the DC charging port (108) when an arc flash event is detected. [10] The vehicle charging system (10) according to claim 1, wherein the housing (102) is a charging plug housing configured to be detachably connected to a charging inlet housing of the charging device (100) of the vehicle (14), wherein the DC charging port (108) is a socket connector configured to be connected to a pin connector of the charging device to supply power to the vehicle via the pin connector. [11] The vehicle charging system (10) according to claim 1, wherein the housing (102) is a charging inlet housing configured to be attached to the vehicle (14) as a holder and configured to accommodate a charging plug housing of the charging device (100), wherein the DC charging port (108) comprises a pin (200) configured to be connected to a socket connector of the charging device to receive power from the charging device. [12] The vehicle charging system (10) according to claim 1, which further comprises a temperature sensor that monitors the temperature of the DC charging port (108), wherein the temperature sensor is operationally coupled to the charge controller (30) to control the charging of the vehicle (14) based on the temperature of the DC charging port. [13] The vehicle charging system (10) according to claim 1, further comprising a light guide extending between a first end (184) and a second end (186), wherein the first end is coupled to the light detector (180) and the second end is positioned near the connection end of the DC charging port (108). [14] The vehicle charging system (10) according to claim 1, which further comprises a UV-sensitive coating (188) on the housing (102) near the connection end (66) of the DC charging port (108) which is activated during the arcing event. [15] A vehicle charging system (10) for an electric vehicle (14), comprising: a housing (102) with a connecting end (66) for connecting to a charging device (100) for the electric vehicle, wherein the housing comprises an inner cavity (134); a DC charging port (108) which is held by the housing in the inner cavity, wherein the DC charging port includes a connecting end for connecting to the charging device and the DC charging port is connected to a power cable (105); a charge controller (30) for controlling the charging process of the vehicle via the DC charging port; and an arc sensor (34) in the inner cavity configured to detect an arc event at the connection end of the DC charging port, wherein the arc sensor comprises a light detector (180), the light detector being a multimodal diversity detector configured to detect light from the arc event in the optical frequency spectrum in a first mode, and configured to detect electromagnetic waves from the arc event in the radio frequency spectrum in a second mode, wherein the arc sensor is operationally coupled to the charge controller to control the vehicle charging when the arc event is detected. [16] The vehicle charging system (10) according to claim 15, wherein the light detector (180) detects optical waves in the first mode and electrical waves in the second mode. [17] The vehicle charging system (10) according to claim 15, wherein the light detector (180) is configured to detect the arc flash event in the first mode with direct line of sight to the arc flash event, wherein the light detector is configured to detect the arc flash event in the second mode without direct line of sight to the arc flash event. [18] The vehicle charging system (10) according to claim 15, wherein the charge controller (30) interrupts the power supply to the DC charging port (108) when the arc flash event is detected. [19] A charging inlet arrangement for an electric vehicle (14), comprising: a housing (102) extending between a front (130) and a rear (132), the housing having a chamber (133) at the rear, the housing having a power connector at the front for receiving a charging plug, the power connector comprising connection channels between the front and the rear; DC charging terminals (108) connected to the housing, each DC charging terminal comprising a mating pin and a termination end opposite the mating pin, the mating pin being positioned in the corresponding connection channel to engage with the charging plug, and the termination end being positioned in the chamber at the rear of the housing; a charge controller (30) which is included in the chamber, wherein the charge controller controls the vehicle charging along the DC charging terminals; and an arc sensor (34) in the inner cavity (134) configured to detect an arc event at the mating pin of the DC charging terminals, the arc sensor comprising a light detector (180) wherein the light detector is a multimodal diversity detector configured in a first mode to detect light from the arc event and configured in a second mode to detect an arc noise signature from the arc event, the arc sensor being operationally coupled to the charge controller to control the vehicle charging when the arc event is detected. [20] The charging inlet arrangement according to claim 19, wherein the light detector (180) detects light in the optical frequency spectrum in the first mode and detects electromagnetic waves in the radio frequency spectrum in the second mode.

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