VEHICLE CHARGING SYSTEM FOR ELECTRIC VEHICLES HAVING ARC DETECTION - Patent application

Abstract

The vehicle charging system (10) includes a housing (102) having a mating end for mating with a charging component (20) for an electric vehicle (14). The vehicle charging system includes DC charging terminals (108) retained in a cavity (134) of the housing and having mating ends for mating with the charging component. The vehicle charging system includes a charge controller (140) for controlling vehicle charging. The vehicle charging system includes an arc sensor (150) in the interior cavity configured to detect an arcing event at the mating end of the DC charging terminal. The arc sensor is operably coupled to the charge controller to control vehicle charging when an arcing event is detected.

Description

[Technical field]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 300,845, entitled "Charging Inlet Arc Detection," filed January 19, 2022, the subject matter of which is incorporated herein by reference in its entirety. [Background technology]

[0002] The subject matter herein generally relates to vehicle charging systems. Electric vehicles (EVs) and hybrid electric vehicles (HEVs) include battery systems for operating the vehicles. The battery systems are charged by the vehicle charging system. For example, a charging connector coupled to a power source is connected to a charging inlet assembly of the vehicle to charge the battery. Summary of the Invention [Problem to be solved by the invention]

[0003] Known vehicle charging systems are not without drawbacks. For example, the temperature of the terminals may increase during charging, which may lead to damage to the charging components. In some cases, arcing may occur between the charging components, which may cause damage to the charging connector and charging inlet assembly. A need remains for an arc detection method for a vehicle charging system of an electric vehicle. [Means for solving the problem]

[0004] In one embodiment, a vehicle charging system for an electric vehicle is provided, the vehicle charging system including a housing having a mating end for mating with a charging component for the electric vehicle. The housing includes an internal cavity. The vehicle charging system includes a DC charging terminal carried by the housing in the internal cavity. The DC charging terminal includes a mating end for mating with the charging component. The DC charging terminal is connected to a power cable. The vehicle charging system includes a charge controller for controlling vehicle charging along the DC charging terminal. The vehicle charging system includes an arc sensor in the internal cavity configured to detect an arcing event at the mating end of the DC charging terminal. The arc sensor is operably coupled to the charge controller to control vehicle charging when an arcing event is detected. The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0005] [Figure 1] FIG. 1 is a schematic diagram of a vehicle charging system according to an exemplary embodiment. [Diagram 2] FIG. 2 is a front perspective view of a charging component according to an exemplary embodiment. [Diagram 3] FIG. 2 is a rear perspective view of a charging component according to an exemplary embodiment. [Figure 4] FIG. 1 is a perspective view of a charge controller according to an exemplary embodiment. [Diagram 5] FIG. 2 is a cross-sectional view of a charging component according to an exemplary embodiment showing a second charging component coupled to the charging component. [Figure 6] FIG. 2 is a cross-sectional view of a charging component according to an exemplary embodiment showing a second charging component coupled to the charging component. [Figure 7] FIG. 2 is a schematic diagram of a charging component according to an exemplary embodiment. [Figure 8] FIG. 2 is a schematic diagram of a charging component according to an exemplary embodiment. [Figure 9]FIG. 2 is a cross-sectional view of a charging component according to an exemplary embodiment showing a second charging component coupled to the charging component. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] FIG. 1 is a schematic diagram 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, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). The vehicle charging system 10 includes a first charging component 20 and a second charging component 40. The first charging component 20 and the second charging component 40 are coupled to each other to charge the battery system 12 of the vehicle 14. In an exemplary embodiment, the first charging component 20 is coupled to the vehicle 14, and the second charging component 40 is coupled to a power source 16 used to charge the battery system 12 of the vehicle 14. For example, the first charging component 20 may be a charging inlet assembly 22 mounted on the vehicle 14, and the second charging component 40 may be a charging connector 42 that may be provided in a charging station or coupled to building wiring of a home or building where the vehicle 14 is parked.

[0007] The first charging component 20 includes a housing 24 that holds a number of charging terminals 26. The charging terminals 26 may be DC charging terminals and / or AC charging terminals.

[0008] The first charging component 20 includes a charge controller 30 that may be used to control vehicle charging. For example, the charge controller 30 may control the delivery of power along the charging terminals 26. The charge controller 30 may communicate with the second charging component 40, for example, to control the second charging component 40. For example, the charge controller 30 may cause the second charging component 40 to turn on the power delivery, turn off the power delivery, increase the power delivery, and / or decrease the power delivery.

[0009] In the exemplary embodiment, first charging component 20 includes a temperature sensor 32 operably coupled to charging controller 30 to monitor the temperature of charging terminals 26. Vehicle charging may be controlled based on the temperature measurements of temperature sensor 32.

[0010] In an exemplary embodiment, first charging component 20 includes an arc sensor 34 operably coupled to charge controller 30 to detect an arcing event within first charging component 20, such as at charging terminals 26. Arc sensor 34 is operably coupled to charge controller 30 to control vehicle charging when an arcing event is detected. For example, when an arcing event is detected, the charge controller immediately shuts off the power supply to stop the charging process and extinguish the arc.

[0011] The second charging component 40 includes a housing 44 that holds a number of charging terminals 46. The charging terminals 46 are configured to mate with the charging terminals 26. In various embodiments, the charging terminals 46 are socket terminals and the charging terminals 26 are pin terminals, although in alternative embodiments, other types of terminals may be used. The charging terminals 46 may be DC charging terminals and / or AC charging terminals.

[0012] The second charging component 40 includes a charge controller 50 that may be used to control vehicle charging. For example, the charge controller 50 may control the power supply along the charging terminals 46. The charge controller 50 may be in communication with the first charging component 20. The charge controller 50 may turn on the power supply, turn off the power supply, increase the power supply, and / or decrease the power supply. The charge controller 50 may control the voltage and / or current supplied by the second charging component 40.

[0013] In the exemplary embodiment, second charging component 40 includes a temperature sensor 52 operably coupled to charging controller 50 to monitor the temperature of charging terminals 46. Vehicle charging may be controlled based on the temperature measurements of temperature sensor 52.

[0014] In the exemplary embodiment, second charging component 40 includes an arc sensor 54 operably coupled to charge controller 50 to detect an arcing event at a mating interface, for example at charging terminals 46. Arc sensor 54 is operably coupled to charge controller 50 to control vehicle charging when an arcing event is detected. For example, when an arcing event is detected, the charge controller immediately shuts off the power supply to stop the charging process and extinguish the arc.

[0015] FIG 2 is a front perspective view of the charging component 100 according to an exemplary embodiment. FIG 3 is a rear perspective view of the charging component 100 according to an exemplary embodiment. In the illustrated embodiment, the charging component 100 is a charging inlet assembly, which may hereinafter be referred to as charging inlet assembly 100. The charging inlet assembly 100 is configured to mate with a complementary charging component (not shown), such as a charging connector or plug charger.

[0016] Charging inlet assembly 100 defines a power connector 101 configured to be electrically connected to a charging connector to charge a battery system of a vehicle, such as an electric vehicle (EV) or a hybrid electric vehicle (HEV). In an exemplary embodiment, charging inlet assembly 100 is configured to mate with a DC fast charging connector, such as an SAE Combo CCS charging connector, in addition to an AC charging connector, such as an SAE J1772 charging connector. In various embodiments, charging inlet assembly 100 has a CCS1 (5-pin) AC configuration. In various other embodiments, charging inlet assembly 100 may have a CCS2 (7-pin) AC configuration. In alternative embodiments, other standard inlet configurations may be used.

[0017] Charging inlet assembly 100 includes a housing 102 configured to be mounted to a vehicle. Housing 102 forms a portion of a power connector 101 for mating with a charging connector. A rear cover 103 (shown in FIG. 2 but removed in FIG. 3 to show the components of charging inlet assembly 100) is coupled to a rear of housing 102 to enclose housing 102 and the internal components of charging inlet assembly 100. Rear cover 103 may be sealed to housing 102 to prevent moisture and debris from entering an internal compartment of housing 102. In the exemplary embodiment, power connector 101 defines a DC charging portion 104 and an AC charging portion 106. The charging portions 104, 106 may form receptacles or openings that receive the plugs of the charging connectors. The charging inlet assembly 100 includes a number of charging terminals 107 for connection to the charging connectors. A power cable 105 is electrically connected to the charging terminals 107 and routed within the vehicle, for example to a battery.

[0018] The DC charging portion 104 is configured to mate with a DC charging connector or DC portion of a charging connector. The DC charging portion may be used for fast charging. In an exemplary embodiment, charging terminals 107 of charging inlet assembly 100 include DC charging terminals 108, such as a pair of DC charging terminals 108, at DC charging portion 104. The DC charging terminals 108 are configured to be electrically connected to a DC charging connector. The charging inlet assembly 100 includes a DC power cable 109 ( FIG. 2 ) that is electrically connected to the DC charging terminals 108. The DC power cable 109 may be terminated directly to the DC charging terminals 108, such as by being crimped or welded to the DC charging terminals 108. In other embodiments, the DC power cable 109 may be electrically connected to the DC charging terminals 108 via a separable interface, such as via a connector that mates with the housing 102 at the rear.

[0019] The AC charging portion 106 is configured to mate with an AC charging connector or AC portion of a charging connector. In an exemplary embodiment, the charging terminal 107 of the charging inlet assembly 100 includes an AC power terminal 110, e.g., a pair of AC power terminals 110, at the AC charging portion 106. The charging terminal 107 of the charging inlet assembly 100 includes a proximal terminal 112 at the AC charging portion 106. The charging terminal 107 of the charging inlet assembly 100 includes a ground terminal 114 at the AC charging portion 106. The charging terminal 107 of the charging inlet assembly 100 includes a communication terminal 116 at the AC charging portion 106. The AC power terminal 110, the proximal terminal 112, the ground terminal 114, and the communication terminal 116 are configured to be electrically connected to the AC charging connector.

[0020] The charging inlet assembly 100 includes an AC cable 111 (FIG. 2) that is electrically connected to corresponding AC terminals 110, 112, 114, 116. The AC cable 111 may be terminated directly to the AC terminals 110, 112, 114, 116, e.g., crimped or welded thereto. In other embodiments, the AC cable 111 may be electrically connected to the AC terminals 110, 112, 114, 116 via a separable interface, e.g., via a connector that mates with the housing 102 at the rear.

[0021] The cables 109, 111 extend from the charging inlet assembly 100 to another component of the vehicle, for example, the battery system of the vehicle. The cables 109, 111 transmit power, for example, to the vehicle's battery. The DC power cable 109 may transmit high voltage for charging the battery, and the AC cable 111 may transmit low voltage for charging the battery. Optionally, one or more of the cables 111 may be electrically connected to a battery control unit (not shown) of the battery system to transmit data, such as data related to charging operations, between the charging inlet assembly 100 and the battery system. For example, the cable 111 may transmit data related to charging start / stop, operating temperature of the power terminals 108 and / or 110, or other charging data. The cable 111 may transmit a proximity signal to the battery system indicating when a charging device is mated to the power connector 101 of the charging inlet assembly 100.

[0022] Charging inlet assembly 100 includes a mounting flange 120 ( FIG. 1 ) coupled to housing 102. Mounting flange 120 is used to couple charging inlet assembly 100 to a vehicle. Mounting flange 120 includes mounting tabs 122 having openings 124 that receive fasteners (not shown) used to secure charging inlet assembly 100 to the vehicle. Other types of mounting mechanisms may be used to secure charging inlet assembly 100 to the vehicle. Mounting flange 120 may include a seal to seal charging inlet assembly 100 to the vehicle.

[0023] In an exemplary embodiment, charging inlet assembly 100 includes a terminal cover 126 ( FIG. 2 ) at a front portion 130 of housing 102. Terminal cover 126 is hinged to mounting flange 120 and / or housing 102. Terminal cover 126 is used to cover portions of housing 102, such as power connector 101. Terminal cover 126 may be used to cover DC charging terminals 108 and / or AC power terminals 110 that are disposed in corresponding terminal channels 128 in housing 102.

[0024] A rear cover 103 is provided at the rear 132 of the housing 102 to block access to a rear chamber 133 at the rear 132 of the housing 102. The rear cover 103 may be clipped or latched to the main portion of the housing 102, for example with a clip or latch. In alternative embodiments, other types of fastening mechanisms, such as clasps, may be used. A perimeter seal may be provided between the rear cover 103 and the housing 102.

[0025] In the exemplary embodiment, housing 102 of charging inlet assembly 100 includes an interior cavity 134 that receives the components of charging inlet assembly 100. A rear chamber 133 is at the rear of interior cavity 134. Interior cavity 134 includes a terminal channel 128 that receives a corresponding charging terminal 107. Interior cavity 134 includes a front chamber 138 at the front that receives a charging connector.

[0026] In the exemplary embodiment, charging inlet assembly 100 includes a charge controller 140 for controlling charging of a vehicle through charging inlet assembly 100. Charge controller 140 is received in interior cavity 134, such as rear chamber 133. Charge controller 140 may be communicatively coupled to other charging components, such as a charging connector or plug, to control charging operations. For example, charge controller 140 may be communicatively coupled to a charging connector via one or more of terminals 107. Charge controller 140 may turn on power, turn off power, increase power, and / or decrease power.

[0027] 4, which is a perspective view of charging controller 140 according to an exemplary embodiment, charging controller 140 includes a circuit board 142, a control device 144, and various other components and circuits for controlling the operation of charging inlet assembly 100. Control device 144 may be a processor or a microcontroller. Control device 144 may include a multi-pin connector coupled to circuit board 142.

[0028] In an exemplary embodiment, the control assembly includes one or more sensors 150 that are used to control the charging operation. The sensors 150 are used to sense operating characteristics of the components or the charging process to control the charging. The sensors 150 are connected to the charge controller 140 and to the circuit board 142, for example by wires or connectors.

[0029] In various embodiments, the sensors 150 include a temperature sensor 152. The temperature sensor 152 monitors the operating temperature of the DC charging terminals 108. The charging operation may be controlled based on the operating temperature of the DC charging terminals 108. For example, the power supply may be decreased as the temperature increases or approaches an acceptable operating temperature. For example, the voltage or current may be reduced. The charging operation may be stopped if the operating temperature of the DC charging terminals 108 exceeds a threshold temperature.

[0030] In various embodiments, sensor 150 includes an arc sensor 160. Arc sensor 160 detects an arcing event within charging inlet assembly 100, such as at the mating end of DC charging terminals 108. Charging operations may be controlled based on the detection of an arcing event. For example, when an arcing event is detected, charging operations are stopped. Current and voltage from the charging connector are immediately stopped to prevent damage to components or the vehicle.

[0031] 5 is a cross-sectional view of the charging component 100 according to an example embodiment, showing a second charging component 60 coupled to the charging component. FIG. 6 is a cross-sectional view of the charging component 100 according to an example embodiment, showing a second charging component 60 coupled to the charging component. In the illustrated embodiment, the charging component 100 is a charging inlet assembly. The second charging component 60 is a charging connector, such as a plug charger.

[0032] Charging terminals 107 are shown in terminal channels 128 of housing 102. Charging terminals 107 mate with charging terminals 62 of charging connector 60. In the illustrated embodiment, charging terminals 107 are pin terminals and charging terminals 62 are socket terminals with spring contacts 64 in the socket configured to electrically connect charging terminals 62 and 107. Spring contacts 64 form a compliant and separable interface. Spring contacts 64 may be susceptible to failure due to overheating, which may lead to an electrical arcing event. Temperature sensor 152 monitors the temperature of charging terminals 107. Arc sensor 160 monitors a mating area, such as mating end 66 of charging terminal 62 or mating end of charging terminal 107, for arcing events.

[0033] The charging terminal 107 includes a mating pin 200 at a mating end 210 of the charging terminal 107 and a cable connector 202 at a rear end 212 of the charging terminal 107. The charging terminal 107 extends along a longitudinal axis. The mating pin 200 is configured to mate with a spring contact 64 of the charging terminal 62 of the charging connector 60. The cable connector 202 is configured to be electrically connected to the power cable 109. In various embodiments, the cable connector 202 is configured to be terminated to the power cable 109 by crimping to the power cable 109. In various other embodiments, the cable connector 202 is terminated to the power cable 109 by other processes, such as welding to a weld tab at the rear end of the charging terminal 107. The cable 109 may extend from the charging terminal 107 perpendicular to the longitudinal axis. Alternatively, the cable 109 may extend from the charging terminal 107 parallel to the longitudinal axis.

[0034] In an exemplary embodiment, the temperature sensor 152 is coupled to the charging terminal 107 at the rear of the charging terminal 107, for example at the cable connector 202. The charging terminal 107 is both electrically and thermally conductive. When the mating pins 200 heat up during charging, the entire charging terminal 107 heats up as well. Such a temperature increase is detected by the temperature sensor 152. In various embodiments, the temperature sensor 152 is a thermistor. The temperature sensor 152 may include a resistance temperature detector.

[0035] The arc sensor 160 detects arcing events in the charging inlet assembly 100, for example at the mating end 210. In various embodiments, the arc sensor 160 monitors an arc noise signature in an electrical circuit to detect an arcing event. For example, noise is induced in a nearby electrical circuit as a result of inductive coupling of arc energy from the charging terminals 107 and / or the power cable 109 to the nearby electrical circuit. The characteristic noise signature of an electrical arc discharge may be between 100-500 kHz. The arc sensor 160 detects the stochastic energy, or noise signature, between 100-500 kHz, generated by an electrical arc. In various other embodiments, the arc sensor 160 monitors an arc UV light signature to detect an arcing event.

[0036] In an exemplary embodiment, arc sensor 160 includes an arc noise signature monitor 170 that monitors an electrical circuit to detect an arc noise signature in the electrical circuit of charging inlet assembly 100 that corresponds to an arcing event. The electrical circuit may be a power circuit, for example along charging terminals 107 and / or power cable 109. The electrical circuit may be a circuit of charge controller 140, for example circuitry on circuit board 142 ( FIG. 3 ). Arc noise signature monitor 170 may monitor a spectrogram of a signal in the electrical circuit to detect an arc noise signature. Arc noise signature monitor 170 may monitor an amplitude rise in the electrical circuit indicative of an arcing discharge.

[0037] Electrical conduction in an arc is a stochastic process that produces a characteristic noise signature, for example between 100-500 kHz. In contrast, charging systems tend to produce chopped or rectified current waveforms at approximately 200 kHz. The arc noise signature can be easily distinguished from the charging current signature in the electrical circuit by the arc noise signature monitor 170, such as by examining a Fourier transform or spectrogram of the signal in the electrical circuit associated with the charging current. In various embodiments, the arc noise signature may be detected by identifying a spike in amplitude above the 100-500 kHz range, which indicates the onset of an arc.

[0038] In various embodiments, charge controller 140 may include an arc fault circuit interrupter (AFCI) device to protect against electrical arcing, e.g., to shut off the charging circuit when an arc is detected. Arc noise signature monitor 170 monitors the electrical circuit to detect an arc noise signature that is conducted in the electrical circuit when an arc fault occurs. Charge controller 140 may include an internal processor in an ACFI device that distinguishes between normal operation and dangerous arcing and automatically opens the circuit to reduce the risk of damage to the system.

[0039] In various embodiments, the arc sensor 160 is connected to other wiring or circuitry to detect the arc noise signature. In various other embodiments, the arc sensor 160 includes a separate dedicated arc detection wire that may be routed from the charging terminals 107 to the circuit board 142 or to another component such as a battery control module. The arc sensor 160 may include a resistor-capacitor-inductor network at the charging terminals 107 or the circuit board 142 to improve sensitivity to the arc signature and minimize sensitivity to normal vehicle electrical noise.

[0040] In an exemplary embodiment, the arc noise signature monitor 170 is electrically coupled to the electrical circuit at or near the cable connector 202 at the rear 212 of the charging terminal 107. The arc noise signature monitor 170 may be coupled to the cable connector 202 or the cable 109. In various embodiments, the arc noise signature monitor 170 includes a current transformer about the power cable 109 for monitoring the electrical signature along the cable 109. In various other embodiments, the arc noise signature monitor 170 includes a Hall sensor adjacent the cable 109 or the cable connector 202 for monitoring the electrical signature along the electrical circuit. In various embodiments, the arc noise signature monitor 170 includes an inductive coil for monitoring the electrical signature along the electrical circuit. The induction coil may be located at or near the cable connector 202 or cable 109. The induction coil may be provided on a circuit board, such as circuit board 142, or on a separate circuit board, such as the circuit board for the temperature sensor system. In various embodiments, the induction coil is extensively tuned with a capacitor. The arc noise signature monitor 170 may include isolation from the power circuit, e.g., from the conductors of the cable 109 or cable connector 202, to prevent damage to the arc noise signature monitor 170. For example, the current transformer, Hall sensor, and / or induction coil may have electrical isolation from conductors carrying the charging current. The electrical isolation may be provided by suitable DC blocking capacitors to isolate the components from the charging current conductors.

[0041] 7 is a schematic diagram of charging component 100 according to an exemplary embodiment. Charging component 100 includes temperature sensor 152 and arc sensor 160 for monitoring charging operations and controlling charging, for example, to shut off charging when an allowable charging temperature is exceeded or an electrical arcing event is detected. In an exemplary embodiment, arc sensor 160 is coupled to temperature sensor 152. For example, a temperature sensing electrical circuit for temperature sensor 152 is monitored by arc sensor 160 to detect an electrical arcing event. Thus, additional sensors or circuits can be avoided, thereby reducing costs and component count. Arc noise signature monitor 170 monitors signals transmitted between temperature sensor 152 and charging controller 140 to detect an arc noise signature in the signal that is indicative of an arcing discharge.

[0042] In an exemplary embodiment, the arc sensor 160 monitors the temperature sensing circuit for an arc noise signature to detect an arc event. For example, noise induced in the temperature electrical circuit as a result of the arc energy may be detected by the arc sensor 160. The arc noise signature monitor 170 may be coupled to the temperature sensing circuit to detect an arc noise signature in the electrical circuit corresponding to an arc event. The arc noise signature monitor 170 may monitor a spectrogram of a signal in the electrical circuit to detect an arc noise signature. The arc noise signature monitor 170 may monitor an amplitude rise in the electrical circuit indicative of an arcing discharge. In various embodiments, the arc noise signature monitor 170 may include an inductive coil in the temperature sensing circuit that may be broadly tuned with a capacitor.

[0043] During an arcing event, electrical noise from the arcing terminal induces noise in the adjacent thermistor conductor of the temperature sensor 152. The induced noise is rectified at a diode junction in the ADC (analog-to-digital converter) used to measure the thermistor resistance, and the rectified noise is added to or subtracted from the actual measured resistance value. Coupling of the arc signal from the charging conductor to the remote thermistor conductor allows the temperature sensing circuit to be used for both temperature sensing and also arc sensing. In an exemplary embodiment, the arc sensor 160 includes a high-pass filter between the ADC input and a second input, such that the second input responds only to the arc signature traveling along the thermistor conductor. The thermistor wiring harness forms an inherent antenna that picks up the MF (medium frequency, 100 kHz to 3 MHz) arc signal radiated from the DC conductor without any additional components. The detection circuitry for the arc sensor 160 may be built into the control unit with few additional components.

[0044] In an exemplary embodiment, the two DC conductors (e.g., power cable 109 and / or terminals) and the two pairs of thermistor conductors of temperature sensor 152 each form a closed loop. Current flow in the loop generates a magnetic field perpendicular to the loop. AC current creates an alternating magnetic field that emits electromagnetic waves. The proximity of both loops results in mutual coupling that carries noise signals from the DC loop to the thermistor loop. Each pair of wires forms a closed loop. The terminations of the thermistor wires are the thermistor at the charging inlet and the ADC input at the ECU. The terminations of the charging cable are the vehicle PDU (power distribution unit) and power conditioning electronics at the charging station (not shown). Arcing at either terminal of the charging inlet induces an MF signal in the charging cable loop. The loop then radiates electromagnetic waves, which induce a replica of the MF signal in the thermistor cable loop. The signal is rectified and smoothed by internal clamping diodes D1 and D2, and then the inherent junction capacitance is applied to the ADC along with the desired thermistor signal. The arc noise signal is added to the temperature signal at the input of the ADC, affecting the resulting output value. The arc sensor 160 monitors the arc noise signature.

[0045] FIG. 8 is a schematic diagram of a charging component 100 according to an exemplary embodiment. The charging component 100 includes a temperature sensor 152 and an arc sensor 160 for monitoring the charging operation and controlling charging, for example, to shut off charging if an allowable charging temperature is exceeded or an electrical arcing event is detected. In the illustrated embodiment, the charging component 100 has an alternative ECU input circuit. The thermistor is wired to the ADC and receives EMI due to arcing. A portion of the signal is routed through a capacitor C1 and then applied to envelope detectors D3 and C2. The rectified and smoothed output appears at the arc signal output 164 of the arc sensor 160 and is used to signal when an arc is detected. C1 blocks DC and passes the MF arc signal. Other electrical components may be used to improve spectral selectivity and avoid potential false positive events.

[0046] 9 is a cross-sectional view of charging component 100 according to an exemplary embodiment showing a second charging component 60 coupled to charging component 100. Charging component 100 includes an arc sensor 160 for monitoring charging operation and controlling charging, for example, to shut off charging if an electrical arcing event is detected.

[0047] In an exemplary embodiment, the arc sensor 160 includes a photodetector 180 for detecting light due to an arc event. For example, the photodetector 180 is a UV photodetector configured to monitor an arc UV light signature. Energy of the proper wavelength and frequency at the photodetector 180 indicates an arc discharge and provides a signal to stop the charging operation. The photodetector 180 may be a photodiode. In an exemplary embodiment, the photodetector 180 is located in the rear chamber 133. The photodetector 180 may be part of the control circuit, for example, mounted on a circuit board or connected by wires to the circuit board 142. The photodetector 180 is configured to detect light in the terminal channel 128, for example, at or near the mating end of the charging terminal 107. In an exemplary embodiment, a light guide 182 extends between the terminal channel 128 and the photodetector 180. The light guide 182 may be an optical fiber. The light guide 182 extends between a first end 184 and a second end 186. The first end 184 is coupled to the photodetector 180. The second end 186 is disposed proximate to the mating end of the charging contacts 107. Light from an arcing event is transmitted from the second end 186 to the first end 184 for detection by the photodetector 180. In an exemplary embodiment, a UV-sensitive coating 188 may be applied to the housing 102 proximate to the mating end of the charging contacts 107, for example, in the terminal channel 128. The UV-sensitive coating 188 is activated during an arcing event to increase the light generated during the arcing event for faster or more reliable monitoring by the photodetector 180.

[0048] Arcing at the mating interface occurs in air. When excited by the arc, nitrogen and oxygen in the air emit light. The two strongest emission lines of oxygen are at 430 nm and 538 nm, which are near UV and deep blue, respectively. Since light is not normally present inside the mated connector, the light output detected by the photodetector 180 will indicate the start of the arc. The photodetector 180 may detect light leaking through small gaps in the mated connector or light routed from the terminal area to the sensor by the light guide 182. The light guide 182 may be routed through the housing 102 without compromising the electrical insulation of the housing 102. Detection of leaking light may be improved by coating the inner walls of the connector with a UV-sensitive phosphor that spreads the light more effectively to the photodetector 180.

Claims

1. A vehicle charging system (10) for an electric vehicle (14), comprising: The vehicle charging system (10) comprises: - a housing (102) having a mating end for mating with a charging component (20) for the electric vehicle, the housing including an interior cavity (134); - a DC charging terminal (108) carried by the housing in the internal cavity, the DC charging terminal including a mating end (210) for mating with the charging component, the DC charging terminal being connected to a power cable (105); and - a charging controller (140) for controlling vehicle charging via said DC charging terminals; an arc sensor (150) in the internal cavity configured to detect an arcing event at the mating end of the DC charging terminal, the arc sensor being operably coupled to the charge controller to control the vehicle charging when the arcing event is detected; and Equipped with A vehicle charging system (10).

2. the charging controller (140) interrupts power supplied to the DC charging terminals (108) when the arcing event is detected. The vehicle charging system (10) of claim 1.

3. the housing (102) is a charging connector housing configured to removably couple to a charging inlet housing of the charging component (20) of the vehicle (14); the DC charging terminal (108) is a socket terminal configured to mate with a pin terminal of the charging component to supply power to the vehicle through the pin terminal. The vehicle charging system (10) of claim 1.

4. the housing (102) is a charging inlet housing configured to be mounted on the vehicle and configured to receive a charging connector housing of the charging component (20); the DC charging terminal (108) includes a pin (200) configured to mate with a socket terminal of the charging component to receive power from the charging component; The vehicle charging system (10) of claim 1.

5. a temperature sensor (152) for monitoring a temperature of the DC charging terminal (108); the temperature sensor is operably coupled to the charging controller to control charging of the vehicle based on the temperature of the DC charging terminals. The vehicle charging system (10) of claim 1.

6. the arc sensor (150) includes an arc noise signature monitor (170) that monitors a signal transmitted between the temperature sensor (152) and the charge controller (140) to detect an arc noise signature in the signal; the arc noise signature is indicative of an arcing discharge; The vehicle charging system (10) of claim 5.

7. the arc sensor (150) includes an arc noise signature monitor (170) that monitors an electrical circuit to detect an arc noise signature in the electrical circuit that corresponds to the arc event; The vehicle charging system (10) of claim 1.

8. the arc noise signature monitor (170) includes a current transformer operably coupled to the power cable (105) to monitor the arc noise signature in the power cable.

8. A vehicle charging system (10) according to claim 7.

9. the arc noise signature monitor (170) includes a Hall sensor operably coupled to the power cable (105) to monitor the arc noise signature in the power cable; 8. A vehicle charging system (10) according to claim 7.

10. the arc noise signature monitor (170) including an inductive coil and a capacitor coupled to the electrical circuit; 8. A vehicle charging system (10) according to claim 7.

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