Vehicle charging system for electric vehicles with arc detection

Abstract

To provide an arc detection method for a vehicle charging system of an electric vehicle.SOLUTION: A vehicle charging system (10) for an electric vehicle (14) includes charging terminals carried by a housing (102) and connected to corresponding power conductors (105) to form power transmission lines (166, 168). A vehicle charging system includes a charge controller (140) for controlling vehicle charging along a transmission line. A vehicle charging system includes an arc sensor assembly (160) coupled to a charge controller. An arc sensor assembly includes a diversity antenna (162) for detecting an arc signature on a power transmission line caused by an arc event. The diversity antenna transmits an arc output signal to the charge controller based on detection of the arc signature.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] This application claims the benefit of U.S. Application No. 63 / 665,335, filed June 28, 2024, the entire subject matter of which is incorporated herein by reference.

[0002] The subject matter herein relates generally to vehicle charging systems. [Background technology]

[0003] Electric vehicles (EVs) and hybrid electric vehicles (HEVs) include battery systems for operating the vehicles. The battery systems are charged by a 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. Known vehicle charging systems are not without drawbacks. For example, terminal temperatures increase during charging, which can lead to damage to the charging components. In some cases, arcing can occur between the charging components, which can damage the charging connector and the charging inlet assembly. Summary of the Invention [Problem to be solved by the invention]

[0004] A need remains for an arc detection method for vehicle charging systems for electric vehicles. [Means for solving the problem]

[0005] 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 charging terminals held by the housing in the internal cavity. Each charging terminal includes a mating end for mating with a charging component. The charging terminals are connected to corresponding power conductors to form a power transmission line. The vehicle charging system includes a charge controller for controlling vehicle charging along the power transmission line. The vehicle charging system includes an arc sensor assembly coupled to the charge controller. The arc sensor assembly includes a diversity antenna for detecting arc signatures on the power transmission lines due to an arc event. The diversity antenna transmits an arc output signal to the charge controller based on detection of the arc signature.

[0006] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a schematic diagram of a vehicle charging system according to an exemplary embodiment; [Figure 2] FIG. 1 is a front perspective view of a charging component according to an exemplary embodiment. [Figure 3] FIG. 1 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 in accordance with an exemplary embodiment. [Figure 5] 10 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] 10 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]1 is a schematic diagram of a vehicle charging system for a vehicle according to an exemplary embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0008] 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 or a hybrid-electric vehicle. 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 the 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 attached to the vehicle 14, and the second charging component 40 may be a charging connector 42 (e.g., a charging plug) that may be provided at a charging station or that may be coupled to building wiring of a home or building where the vehicle 14 is parked.

[0009] First charging component 20 includes a housing 24 that holds a plurality of charging terminals 26 and power conductors 28 coupled to charging terminals 26. Charging terminals 26 may be DC and / or AC charging terminals. Power conductors 28 may be power cables, bus bars, or other types of conductors.

[0010] First charging component 20 includes a charge controller 30 that can be used to control vehicle charging. For example, charge controller 30 can control the power supply along charging terminals 26. Charge controller 30 can communicate with second charging component 40, for example, to control second charging component 40. For example, charge controller 30 can cause second charging component 40 to turn on the power supply, turn off the power supply, increase the power supply, and / or decrease the power supply.

[0011] In the exemplary embodiment, first charging component 20 includes a temperature sensor 32 operably coupled to charge controller 30 to monitor the temperature of charging terminals 26. Vehicle charging can be controlled based on the temperature measurements of temperature sensor 32. Temperature sensor 32 can be used for arc detection, such as by monitoring for temperature spikes or temperatures above a threshold temperature, which may be higher than the normal operating temperature range. The temperature sensor assembly (including the cable) can act as an antenna to detect EMI from arcing and thus operate as an arc sensor.

[0012] In the exemplary embodiment, first charging component 20 includes an arc sensor assembly 34 operably coupled to charge controller 30 to monitor an arc signature of an arcing event traveling along a power line within first charging component 20, e.g., at charging terminals 26 and / or along power conductors 28. Arc sensor assembly 34 is operably coupled to charge controller 30 to control vehicle charging based on the detected arc signal or the like. For example, when an arcing event is detected, charge controller 30 can immediately interrupt the power supply to stop the charging process and extinguish the arc. Charge controller 30 can communicate with second charging component 40 to, for example, interrupt the power supply to stop the charging process.

[0013] In the exemplary embodiment, arc sensor assembly 34 includes a diversity antenna 36 for improved identification of arcing events and control of charging operations. Charge controller 30 operates based on signals from diversity antenna 36. Diversity antenna 36 provides at least one of position diversity, radiation pattern diversity, polarization diversity, frequency diversity, and mode diversity for improved identification of arcing events and control of charging operations.

[0014] In an exemplary embodiment, the arc sensor assembly 34 can identify a false-positive arc event. For example, the diversity antenna 36 can be used to distinguish arc signatures to identify a false-positive arc event and control charging operations, such as maintaining the charging process, if the arc event is identified as a false positive. In an exemplary embodiment, the arc sensor assembly 34 can distinguish between power line arc signals generated by the vehicle and arc signals or noise generated from external sources, such as sources other than the vehicle charging system. By distinguishing between signals generated by the vehicle charging system and signals generated from other sources (e.g., noise), vehicle charging can be appropriately controlled for improved operation of the vehicle charging system.

[0015] In an exemplary embodiment, the diversity antenna 36 includes one or more diversity antenna elements 38. The diversity antenna elements 38 provide position diversity, radiation pattern diversity, polarization diversity, frequency diversity, and / or mode diversity for proper monitoring of the vehicle charging signal and identification of arcing events to control charging operations. One or more of the diversity antenna elements 38 can be positioned proximate to the power line to monitor the electromagnetic field of the signal along the power line. One or more of the diversity antenna elements 38 can be positioned away from the power line within the vehicle to monitor external signals (e.g., noise) and can be used to distinguish the vehicle charging signal from external signals transmitted along the power line. In an exemplary embodiment, the diversity antenna elements 38 may include e-field antenna elements and / or h-field antenna elements and / or b-field antenna elements. The antenna elements 38 may measure electrostatic signals. The antenna elements 38 may measure magnetic signals. In alternative embodiments, other types of antenna elements may be used. In an exemplary embodiment, the diversity antenna elements 38 may include omnidirectional antenna elements and / or directional antenna elements. The directional antenna elements may point in the direction of the power lines and receive electromagnetic fields from the power lines, while the omnidirectional antenna elements may receive signals from external sources as well as the power lines to help distinguish between the signals. Different diversity antenna elements 38 can detect signals in different frequency ranges. The arc sensor assembly 34 can include processing devices, such as a noise blanker, one or more receivers, a digital signal processor, a beam steering device, a diversity switching device, a neural network, a frequency diplexer, etc., to process the signals.

[0016] The arc sensor assembly 34 (and / or components of the arc sensor assembly 34) may be provided in various locations within the vehicle charging system 10. For example, the arc sensor assembly 34 may be located within or on the first charging component 20. In various other embodiments, the arc sensor assembly 34 may be located within or on the vehicle 14, such as within or on the battery system 12. For example, the arc sensor assembly 34 may be incorporated into a battery distribution unit (BDU) or other component of the battery system 12.

[0017] The second charging component 40 includes a housing 44 that holds a plurality of charging terminals 46 and a power conductor 48 coupled to the charging terminals 26. 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 other types of terminals may be used in alternative embodiments. The charging terminals 46 may be DC charging terminals and / or AC charging terminals. The power conductors 48 may be power cables, bus bars, or other types of conductors.

[0018] The second charging component 40 includes a charge controller 50 that can be used to control vehicle charging. For example, the charge controller 50 can control the power supply along the charging terminals 46. The charge controller 50 can be in communication with the first charging component 20. The charge controller 50 can turn the power supply on, turn the power supply off, increase the power supply, and / or decrease the power supply. The charge controller 50 can control the voltage and / or current supplied by the second charging component 40.

[0019] In the exemplary embodiment, second charging component 40 includes a temperature sensor 52 operably coupled to charge controller 50 to monitor the temperature of charging terminals 46. Vehicle charging can be controlled based on the temperature measurements of temperature sensor 52. Temperature sensor 52 can be used for arc detection, such as by monitoring for temperature spikes or temperatures above a threshold temperature, which may be higher than the normal operating temperature range. The temperature sensor assembly (including the cable) can act as an antenna to detect EMI from arcing and thus operate as an arc sensor.

[0020] In the exemplary embodiment, second charging component 40 includes an arc sensor assembly 54 operably coupled to charge controller 50 to monitor an arc signature of an arcing event traveling along a power line within second charging component 40, e.g., at charging terminal 46 and / or along power conductor 48. Arc sensor assembly 54 is operably coupled to charge controller 50 to control vehicle charging based on the detected arc signal or the like. For example, when an arcing event is detected, charge controller 50 can immediately interrupt the power supply to stop the charging process and extinguish the arc. Charge controller 50 can communicate with first charging component 20 to, for example, interrupt the power supply to stop the charging process.

[0021] In the exemplary embodiment, arc sensor assembly 54 includes a diversity antenna 56 for improved identification of arcing events and control of charging operations. Charge controller 50 operates based on signals from diversity antenna 56. Diversity antenna 56 provides at least one of position diversity, radiation pattern diversity, polarization diversity, frequency diversity, and mode diversity for improved identification of arcing events and control of charging operations.

[0022] In an exemplary embodiment, the arc sensor assembly 54 can identify a false-positive arc event. For example, the diversity antenna 56 is used to distinguish arc signatures to identify a false-positive arc event and control charging operations, such as maintaining the charging process, if the arc event is identified as a false positive. In an exemplary embodiment, the arc sensor assembly 54 can distinguish between power line arc signals generated by the power source and arc signals or noise generated from external sources, such as sources other than the charging system. By distinguishing between signals generated by the charging system and signals generated from other sources (e.g., noise), vehicle charging can be appropriately controlled for improved operation of the charging system.

[0023] In an exemplary embodiment, diversity antenna 56 includes one or more diversity antenna elements 58. Diversity antenna elements 58 provide position diversity, radiation pattern diversity, polarization diversity, frequency diversity, and / or mode diversity for proper monitoring of the vehicle charging signal and identification of arcing events to control charging operations. One or more of diversity antenna elements 58 can be positioned proximate to the power line to monitor the electromagnetic field of the signal along the power line. One or more of diversity antenna elements 58 can be positioned away from the power line, such as in a charging station, to monitor external signals (e.g., noise), which can be used to distinguish the vehicle charging signal from external signals transmitted along the power line. In an exemplary embodiment, diversity antenna elements 58 may include e-field antenna elements and / or h-field antenna elements and / or b-field antenna elements. Antenna elements 58 may measure electrostatic signals. Antenna elements 58 may measure magnetic signals. In alternative embodiments, other types of antenna elements may be used. In an exemplary embodiment, diversity antenna elements 58 may include omnidirectional antenna elements and / or directional antenna elements. Directional antenna elements may point in the direction of the power lines and receive electromagnetic fields from the power lines, while omnidirectional antenna elements may receive signals from external sources as well as the power lines to help distinguish between signals. Different diversity antenna elements 58 can detect signals in different frequency ranges. The arc sensor assembly 54 can include processing devices, such as a noise blanker, one or more receivers, a digital signal processor, a beam steering device, a diversity switching device, a neural network, a frequency diplexer, etc., to process the signals.

[0024] Arc sensor assembly 54 (and / or components of arc sensor assembly 54) may be provided in various locations within vehicle charging system 10. For example, arc sensor assembly 54 may be located in or on a charging plug. In various other embodiments, arc sensor assembly 54 may be located in or on a charging station.

[0025] Figure 2 is a front perspective view of the charging component 100 according to an exemplary embodiment. Figure 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 the 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.

[0026] Charging inlet assembly 100 defines a power connector 101 configured to electrically connect to a charging connector for charging 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 or an NACS 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 other various embodiments, charging inlet assembly 100 can have a CCS2 (7-pin) AC configuration. In alternative embodiments, other standard inlet configurations, such as an NACS configuration, can be used.

[0027] Charging inlet assembly 100 includes a housing 102 configured to be mounted to a vehicle. Housing 102 forms a portion of 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 the 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 the interior compartment of housing 102. In an exemplary embodiment, power connector 101 defines a DC charging portion 104 and an AC charging portion 106. Charging portions 104, 106 may form a receptacle or opening that receives a plug of the charging connector. The charging inlet assembly 100 includes a plurality of charging terminals 107 for connecting to a charging connector. Power conductors 105 are electrically connected to the charging terminals 107 and are routed within the vehicle, such as to a battery. The power conductors 105 may be power cables, bus bars, or other types of conductors. The charging terminals 107 and the power conductors 105 form a power transmission line through the vehicle.

[0028] DC charging portion 104 is configured to mate with a DC charging connector or a DC portion of a charging connector. The DC charging portion can be used for fast charging. In an exemplary embodiment, charging terminal 107 of charging inlet assembly 100 includes DC charging terminals 108, such as a pair of DC charging terminals 108, in DC charging portion 104. DC charging terminals 108 are configured to be electrically connected to a DC charging connector. Charging inlet assembly 100 includes DC power conductors 109 ( FIG. 2 ) electrically connected to DC charging terminals 108. DC power conductors 109 can be terminated directly to DC charging terminals 108, such as by crimping or welding to DC charging terminals 108. In other embodiments, DC power conductors 109 can be electrically connected to DC charging terminals 108 via a separable interface, such as via a connector that mates with housing 102 at the rear. DC charging terminals 108 and DC power conductors 109 form a power transmission line through the vehicle.

[0029] AC charging portion 106 is configured to mate with an AC charging connector or an AC portion of a charging connector. In the exemplary embodiment, charging terminal 107 of charging inlet assembly 100 includes AC power terminal 110, e.g., a pair of AC power terminals 110, at AC charging portion 106. Charging terminal 107 of charging inlet assembly 100 includes a proximity terminal 112 at AC charging portion 106. Charging terminal 107 of charging inlet assembly 100 includes a ground terminal 114 at AC charging portion 106. Charging terminal 107 of charging inlet assembly 100 includes a communication terminal 116 at AC charging portion 106. AC power terminal 110, proximity terminal 112, ground terminal 114, and communication terminal 116 are configured to be electrically connected to the AC charging connector.

[0030] Charging inlet assembly 100 includes AC conductors 111 (FIG. 2) electrically connected to corresponding AC terminals 110, 112, 114, 116. AC conductors 111 can be terminated directly to AC terminals 110, 112, 114, 116, e.g., crimped or welded thereto. In other embodiments, AC conductors 111 can be electrically connected to AC terminals 110, 112, 114, 116 via a separable interface, e.g., via a connector that mates with housing 102 at the rear. AC charging terminals 110 and AC power conductors 111 form a power transmission line through the vehicle.

[0031] Conductors 109, 111 extend from charging inlet assembly 100 to other components of the vehicle, such as the vehicle's battery system. Conductors 109, 111 transmit power to the vehicle's battery, etc. DC power conductors 109 can transmit high voltage for charging the battery, and AC conductors 111 can transmit low voltage for charging the battery. Optionally, one or more of conductors 111 can 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 charging inlet assembly 100 and the battery system. For example, conductors 111 can transmit data related to charging start / stop, operating temperatures of power terminals 108 and / or 110, or other charging data. Conductors 111 can send a proximity signal to the battery system indicating when a charging device is mated with power connector 101 of charging inlet assembly 100.

[0032] 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 with 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.

[0033] In the exemplary embodiment, charging inlet assembly 100 includes a terminal cover 126 ( FIG. 2 ) on the front 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 can be used to cover DC charging terminals 108 and / or AC power terminals 110 positioned in corresponding terminal channels 128 in housing 102.

[0034] The rear cover 103 is provided at the rear 132 of the housing 102 to close 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, using a clip or latch. In alternative embodiments, other types of fastening mechanisms, such as fasteners, may be used. A perimeter seal may be provided between the rear cover 103 and the housing 102.

[0035] In the exemplary embodiment, housing 102 of charging inlet assembly 100 includes an internal cavity 134 that receives the components of charging inlet assembly 100. Rear chamber 133 is at the rear of internal cavity 134. Internal cavity 134 includes terminal channels 128 that receive corresponding charging terminals 107. Terminal channels 128 may be separated from each other and from other components by walls of housing 102. Internal cavity 134 includes a front chamber 138 at the front that receives a charging connector.

[0036] In the exemplary embodiment, charging inlet assembly 100 includes a charge controller 140 for controlling charging of the vehicle through charging inlet assembly 100. Charge controller 140 (or components thereof) may be received in an 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 the charging operation, or may be communicatively coupled to another charge controller within the vehicle (e.g., in a battery distribution unit) to control the charging process. Charge controller 140 may be communicatively coupled to the charging connector via one or more of terminals 107. The charge controller 140 can turn the power supply on, turn the power supply off, increase the power supply, and / or decrease the power supply. The charge controller 140 can be located remotely from the housing 102, such as in a battery control module of a vehicle charging system.

[0037] 4, which is a perspective view of charge controller 140 according to an exemplary embodiment, charge controller 140 includes a circuit board 142, a control device 144, and various other components and circuits for controlling the operation of charge 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.

[0038] In the exemplary embodiment, the control assembly includes one or more sensors 150 used to control the charging operation. The sensors 150 are used to sense the operating characteristics of 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.

[0039] In various embodiments, the sensor 150 includes a temperature sensor 152. The temperature sensor 152 monitors the operating temperature of the DC charging terminals 108. Charging operations can be controlled based on the operating temperature of the DC charging terminals 108. For example, as the temperature increases or approaches an acceptable operating temperature, power delivery can be reduced. For example, the voltage or current can be reduced. Charging operations can be stopped if the operating temperature of the DC charging terminals 108 exceeds a threshold temperature. The temperature sensor 152 can be used for arc detection, such as by monitoring for temperature spikes or temperatures exceeding a threshold temperature, which may be higher than the normal operating temperature range.

[0040] In various embodiments, sensor 150 includes one or more current sensors 154 that monitor the current transmitted along the power line. A current spike or a current above a threshold (e.g., above a normal charging level) can indicate an arcing event. Charging operations can be controlled based on the sensed current. For example, if an arcing event is detected, charging operations can be stopped. Sensor 150 can include additional systems to help identify false-positive arcing events and / or to reduce noise, thereby allowing charging to continue if the detected event is a false-positive arcing event.

[0041] In alternative embodiments, other types of sensors 150, such as optical sensors configured to detect arcing events, may be provided. For example, the optical sensor may include a light detector, such as a photodiode. Various types of sensors (temperature, current, optical, antenna, vibration, etc.) may use different monitoring modes to monitor for arcing events, thereby providing multi-mode arc detection.

[0042] In the exemplary embodiment, sensor 150 includes an arc sensor assembly 160 coupled to charge controller 140. Arc sensor assembly 160 is configured to be positioned within the vehicle, for example, proximate to an electric power line, to detect an arc signature on the electric power line due to an arcing event. Arc sensor assembly 160 transmits an arc output signal to charge controller 140. The arc output signal can be based on the detection of the arc signature.

[0043] Arc sensor assembly 160 is operably coupled to charge controller 140 to monitor an arc signature of an arc event traveling along the power line within first charging component 20, e.g., at charging terminal 107, and / or along power conductor 105. Arc sensor assembly 160 is operably coupled to charge controller 140 to control vehicle charging based on the detected arc signal, etc. For example, when an arc event is detected, charge controller 140 can immediately interrupt the power supply to stop the charging process and extinguish the arc. Charge controller 140 can communicate with second charging component 40 to, for example, interrupt the power supply to stop the charging process.

[0044] In the exemplary embodiment, arc sensor assembly 160 includes a diversity antenna 162 for improved identification of arcing events and control of charging operations. Charging controller 140 operates based on signals from diversity antenna 162. Diversity antenna 162 provides at least one of position diversity, radiation pattern diversity, polarization diversity, frequency diversity, and mode diversity for improved identification of arcing events and control of charging operations. Arc sensor assembly 160 may include processing devices, such as a noise blanker, one or more receivers, a digital signal processor, a beam steering device, a diversity switching device, a neural network, a frequency diplexer, or the like, for processing the signals.

[0045] In an exemplary embodiment, arc sensor assembly 160 can identify a false-positive arc event. For example, diversity antenna 162 is used to distinguish arc signatures to identify a false-positive arc event and control charging operations, such as maintaining the charging process, when the arc event is identified as a false positive. In an exemplary embodiment, arc sensor assembly 160 can distinguish between power line arc signals generated by the vehicle and arc signals or noise generated from external sources, such as sources other than the vehicle charging system. By distinguishing between signals generated by the vehicle charging system and signals generated from other sources (e.g., noise), vehicle charging can be appropriately controlled for improved operation of the vehicle charging system.

[0046] In the exemplary embodiment, diversity antenna 162 includes one or more diversity antenna elements 164. Diversity antenna elements 164 can detect signals around the vehicle, such as signals along power lines. Diversity antenna 162 can include one or more antenna circuits operably coupled to diversity antenna elements 164 and other components for transmitting signals from diversity antenna 162. The antenna circuits can include or be connected to processing devices, such as digital signal processors, neural networks, frequency diplexers, etc., to process the signals.

[0047] In an exemplary embodiment, diversity antenna element 164 provides position diversity and / or radiation pattern diversity and / or polarization diversity and / or frequency diversity and / or mode diversity for proper monitoring of vehicle charging signals and identification of arcing events to control charging operations.

[0048] One or more of the diversity antenna elements 164 can be placed in proximity to the power line to monitor the electromagnetic field of signals along the power line. One or more of the diversity antenna elements 164 can be placed away from the power line within the vehicle to monitor external signals (e.g., noise) that can be used to distinguish the vehicle charging signal from external signals transmitted along the power line.

[0049] In an exemplary embodiment, the diversity antenna elements 164 may include e-field antenna elements, h-field antenna elements, and / or b-field antenna elements. The antenna elements 164 may measure electrostatic signals. The antenna elements 164 may measure magnetic signals. In alternative embodiments, other types of antenna elements may be used. In an exemplary embodiment, the diversity antenna elements 164 may include omnidirectional antenna elements and / or directional antenna elements. The directional antenna elements may point toward the power lines and receive electromagnetic fields from the power lines, while the omnidirectional antenna elements may receive signals from external sources as well as the power lines to help distinguish between signals. Different diversity antenna elements 164 may detect signals within different frequency ranges.

[0050] In an exemplary embodiment, arc sensor assembly 160 can determine the magnitude and phase of the power line arc signal. Arc sensor assembly 160 can distinguish between common mode and differential mode signals to distinguish between a vehicle charging signal transmitted along the power line from a monitored vehicle and an external signal generated from a source other than the monitored vehicle's vehicle charging system. In differential mode, the power line signals may be equal in magnitude and opposite in phase, essentially canceling each other, indicating that the detected signal is a vehicle charging signal. However, in common mode, because the signal is generated from a different source (e.g., an arcing event in a nearby vehicle charging at a different charging station), the signal is received by both power lines and is equal in magnitude and in phase, indicating that the signal is generated from an external source, thus identifying a false positive arc event. Distinguishing between common mode and differential mode allows the system to accurately distinguish between an arc event and a false positive arc event.

[0051] Arc sensor assembly 160 (and / or components of arc sensor assembly 160) may be provided in various locations within vehicle charging system 10. For example, arc sensor assembly 160 may be located within or on charging inlet assembly 100. In various other embodiments, arc sensor assembly 160 may be located within or on the vehicle, for example, within or on the battery system. For example, arc sensor assembly 160 may be incorporated into a battery distribution unit (BDU) or other component of the battery system.

[0052] In various embodiments, arc sensor assembly 160 is integrated into charge controller 140, such as integrated into circuit board 142. In various other embodiments, arc sensor assembly 160 can be located remotely from the charge controller and coupled to the charge controller via a wired or wireless connection. The signal from arc sensor assembly 160 can be processed, such as by low-noise amplification and / or filtering along the signal path. Various types of connections can allow for greater flexibility in the location of the detector circuitry compared to an antenna element. Arc sensor assembly 160 can be located within housing 102, such as in interior cavity 134. Thus, the arc sensor assembly 160 can be positioned proximate the charging terminals 107 and / or the ends of the power conductors 105. In various other embodiments, the arc sensor assembly 160 can be positioned away from the housing 102, for example, along the power conductors 105 outside the housing 102, or in a battery assembly such as a battery distribution unit (BDU).

[0053] Diversity antenna 162 transmits one or more outputs (e.g., arc signal outputs) to charge controller 140. Charge controller 140 may include a processing device, such as a microcontroller, processor, digital signal processor, neural network, frequency diplexer, etc., to process the signals. Charge controller 140 is used to control charging operations. For example, charge controller 140 can turn on the power supply, turn off the power supply, increase the power supply, and / or decrease the power supply based on the signal from antenna element 164 (e.g., based on the current output signal). For example, if an arc 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.

[0054] Figure 5 is a cross-sectional view of the charging component 100 according to an exemplary embodiment, showing a second charging component 60 coupled to the charging component. Figure 6 is a cross-sectional view of the charging component 100 according to an exemplary 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.

[0055] Charging terminal 107 is shown in terminal channel 128 of housing 102. Charging terminal 107 mates with charging terminal 62 of charging component 60. In the illustrated embodiment, charging terminal 107 is a pin terminal, and charging terminal 62 is a socket terminal with spring contacts 64 in the socket configured to electrically connect charging terminal 62 and charging terminal 107. Spring contacts 64 form a flexible, separable interface. Spring contacts 64 may be prone to failure due to overheating, which may lead to an electrical arcing event. Temperature sensor 152 monitors the temperature of charging terminal 107. Diversity antenna element 164 monitors electromagnetic fields, such as power line radio frequency signals, for arcing events, such as at the mating end 66 of charging terminal 62 or the mating end of charging terminal 107.

[0056] 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 component 60. The cable connector 202 is configured to be electrically connected to the power conductor 109. In various embodiments, the cable connector 202 is configured to be terminated to the power conductor 109 by crimping the power conductor 109. In other various embodiments, the cable connector 202 is terminated to the power conductor 109 by other processes, such as by being welded to a weld tab at the rear end of the charging terminal 107. The conductor 109 can extend from the charging terminal 107 perpendicular to the longitudinal axis. Alternatively, the conductor 109 can extend from the charging terminal 107 parallel to the longitudinal axis.

[0057] 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 pin 200 heats up during charging, the entire body of the charging terminal 107 heats up as well. This 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.

[0058] Arc sensor assembly 160 monitors signals around the vehicle, such as vehicle charging / arcing signals along the power line generated by the vehicle, as well as arcing signals or noise generated from external sources, such as sources other than the vehicle charging system. By monitoring electromagnetic fields, arc sensor assembly 160 can detect and distinguish arcing events occurring within the monitored vehicle from arcing events or other noise occurring on another vehicle or from another external source. By monitoring electromagnetic fields, arc sensor assembly 160 can detect false-positive arcing events occurring outside the power line, such as on a different vehicle at a charging station, or other external events that could lead to RF signal spikes on the power line. By detecting an arcing event, arc sensor assembly 160 can signal charge controller 140 to stop charging operations to protect the components of charge inlet assembly 100 and the vehicle.

[0059] In various embodiments, the arc sensor assembly 160 monitors an arc noise signature to detect an arc event. For example, arc noise is generated by an arc event, such as in the radio frequency range, as a result of arc energy. The characteristic noise signature of an electric arc may be in a predetermined range, such as 1 kHz to 100 GHz. The characteristic noise signature of an electric arc may be in a more specific range, such as 100 to 500 kHz. The arc sensor assembly 160 detects a stochastic energy or noise signature generated by an electric arc. In an exemplary embodiment, the arc sensor assembly 160 can monitor the power line of the charging inlet assembly 100 to detect an arc noise signature on the power line corresponding to an arc event. The arc sensor assembly 160 can monitor the current along the charging terminal 107 and / or the power conductor 109.

[0060] In various embodiments, charge controller 140 can include an arc fault circuit interrupter (AFCI) device to protect against electrical arcs, for example, to shut down the charging circuit when an arc is detected. Diversity antenna element 164 monitors the electrical circuit for an arc noise signature to detect an arc noise signature conducted on the power line when an arc fault occurs. Charge controller 140 can include an internal processor in the AFCI device that distinguishes between normal operation and a dangerous arc and automatically opens the circuit to reduce the risk of damage to the system.

[0061] In various embodiments, arc sensor assembly 160 is connected to other wiring or circuitry to detect the arc noise signature. Arc sensor assembly 160 can be located in the battery, such as in a battery distribution unit (BDU), rather than in the charging inlet housing. In various other embodiments, arc sensor assembly 160 includes a separate, dedicated arc detection wire, which can be routed from charging terminal 107 to circuit board 142 or to another component, such as a battery control module. Arc sensor assembly 160 can include a resistor-capacitor-inductor network or filter on charging terminal 107 or circuit board 142 to improve sensitivity to the arc signature and minimize sensitivity to normal vehicle electrical noise.

[0062] In an exemplary embodiment, diversity antenna element 164 is electrically coupled to the power line at or near cable connector 202 at rear 212 of charging terminal 107. Diversity antenna element 164 may be coupled to cable connector 202 or conductor 109. In various embodiments, diversity antenna element 164 may be positioned between two different power lines to measure signals from both power lines. In various embodiments, a different diversity antenna element 164 may be provided on each of the power lines to monitor each power line and monitor electrical signatures along such power lines. The diversity antenna elements 164 may be located elsewhere in the vehicle, for example, away from the power lines (e.g., on the front bumper, on the vehicle roof, in the trunk, etc.) The arc sensor assembly 160 may compare signals from the different diversity antenna elements 164 to determine if an arcing event is occurring and / or to determine if a false positive arcing event is occurring.

[0063] 7 is a schematic diagram of a vehicle charging system for a vehicle according to an exemplary embodiment. An arc sensor assembly 160 is coupled to a charge controller 140. A diversity antenna 162 detects signals, such as charging signatures, arcing signatures, and noise, within and around the vehicle, for example, along power lines 166 and 168. The diversity antenna 162 transmits an output signal to the charge controller 140 to control charging operations. For example, the diversity antenna 162 can transmit a charging output signal indicative of charging operations to the charge controller 140. The diversity antenna 162 can transmit an arcing output signal to the charge controller 140 based on the detection of an arcing signature.

[0064] In the exemplary embodiment, diversity antenna 162 includes multiple diversity antenna elements 164. For example, in the illustrated embodiment, diversity antenna 162 includes a first diversity antenna element 170, a second diversity antenna element 172, a third diversity antenna element 174, and a fourth diversity antenna element 176. In alternative embodiments, diversity antenna 162 may include more or fewer diversity antenna elements 164. Diversity antenna elements 170, 172, 174, 176 provide at least one of position diversity, radiation pattern diversity, polarization diversity, frequency diversity, and mode diversity.

[0065] In the illustrated embodiment, the first diversity antenna element 170 and the second diversity antenna element 172 are positioned proximate to the power lines 166, 168. The first diversity antenna element 170 and the second diversity antenna element 172 are positioned proximate to each other. In the exemplary embodiment, the first diversity antenna element 170 and the second diversity antenna element 172 operate in different receive modes to provide diversity signaling. For example, the first diversity antenna element 170 includes a patch antenna element operating in an e-field receive mode, and the second diversity antenna element 172 includes a coil antenna element operating in an h-field receive mode. The first diversity antenna element 170 and the second diversity antenna element 172 provide simultaneous reception of signals to improve the reliability of a clear indication of an arc. For example, near-field noise has strong e-field and h-field components, while far-field noise has a predominantly e-field component. Using both diversity antenna elements 170, 172 with different reception modes along with simultaneous detection avoids generating false positive results by reducing the likelihood of triggering arc detection for more distant external noise signals (e.g., signals from adjacent vehicles in a bank of charging stations, nearby welding arcs, spark plug noise from an internal combustion engine, or other similar sources).

[0066] In various other embodiments, instead of using two diversity antenna elements using different receive modes, the first diversity antenna element 170 and the second diversity antenna element 172 may be different types of antennas with different directional capabilities. For example, the first diversity antenna element 170 may be an omnidirectional antenna, and the second diversity antenna element 172 may be a directional antenna element. The directional antenna element may be oriented toward the power lines 166, 168 to directionally receive signals from the power lines 166, 168 and ignore or block signals from other directions. The omnidirectional antenna element may receive signals from all directions and receive both signals from the power lines 166, 168 and noise from other external sources. Comparing signals from two different types of antennas avoids generating false positive results by reducing the likelihood of triggering arc detection due to external noise signals from directions other than the direction of the power lines 166, 168.

[0067] In the exemplary embodiment, third diversity antenna element 174 and fourth diversity antenna element 176 are positioned away from power lines 166, 168 on the vehicle, in contrast to first diversity antenna element 170 and second diversity antenna element 172, which are positioned closer to power lines 166, 168 on the vehicle. First diversity antenna element 170 and second diversity antenna element 172 are more closely or strongly coupled to power lines 166, 168 compared to third diversity antenna element 174 and fourth diversity antenna element 176, and more accurately discriminate signals from power lines 166, 168. Third diversity antenna element 174 and fourth diversity antenna element 176 can receive external signals. Diversity antenna 162 can desensitize the vehicle charging system based on external signals received by third diversity antenna element 174 and fourth diversity antenna element 176. For example, diversity antenna 162 can cancel or negate external signals received by third diversity antenna element 174 and fourth diversity antenna element 176 that are also sensed by first diversity antenna element 170 and second diversity antenna element 172.

[0068] In the exemplary embodiment, arc sensor assembly 160 includes a noise blanker 180 and one or more receivers 182. Receiver 182 is configured to receive signals from one or more of diversity antenna elements 164. The signals may be processed by the receiver or transmitted from the receiver to another component for processing. Noise blanker 180 is configured to block certain signals received by diversity antenna 162, such as signals from external sources, from receiver 182. Noise blanker 180 improves the operation of diversity antenna 162 by blocking signals (e.g., signals from external sources) that are not related to the vehicle charging operation of the vehicle being monitored. For example, noise blanker 180 is configured to block signals received by diversity antenna 162 when an external trigger event is detected from a source other than the vehicle charging system. In one example, external signals sensed by third diversity antenna element 174 and fourth diversity antenna element 176 may be used by noise blanker 180 to block such associated signals at receivers associated with first diversity antenna element 170 and second diversity antenna element 172. Noise blanker 180 is configured to reduce the adverse effects of noise on the arc detection system. For example, the noise blanker 180 can isolate the receiver 182 from external noise for a duration or period during which the external noise is detected, so that the noise is not transmitted to the receiver 182 or the effect of the noise is reduced, improving signal throughput. The signal-to-noise ratio is improved because periods of silence (erasure) differ less in amplitude from the desired signal than noise pulses.

[0069] In the exemplary embodiment, third diversity antenna element 174 is positioned proximate to a vehicle motor inverter 178 to detect switching transients caused by inverter operation. Noise blanker 180 is configured to block signals at receiver 182 based on the switching transients detected by the third diversity antenna element.

[0070] In the exemplary embodiment, the arc sensor assembly 160 includes a signal processing device 190 that processes signals from the diversity antenna 162. The signal processing device 190 includes a beam steering device 192. The beam steering device 192 is configured for beam steering detection to determine the direction of arrival of a signal at the diversity antenna 162. The beam steering device 192 is configured to determine whether the signal is emanating directionally from the power lines 166, 168 or from an external source. In the exemplary embodiment, the signal processing device 190 is configured for diversity switching to select, from the plurality of diversity antenna elements 164, the diversity antenna element 164 having the least noise. The receiver 182 can receive and process signals from the diversity antenna elements 164 with minimal noise. In an exemplary embodiment, the signal processing device 190 is configured for phase-coherent summation and analysis of different combinations of signals from the diversity antennas.

Claims

1. A vehicle charging system (10) for an electric vehicle (14), comprising: a housing (102) having a mating end for mating with a charging component (40) for the electric vehicle, the housing including an interior cavity (134); charging terminals (107) held by the housing in the internal cavity, each charging terminal including a mating end (210) for mating with the charging component, the charging terminals connected to corresponding power conductors (105) to form power lines (166, 168); a charging controller (140) for controlling charging of vehicles along the power line; an arc sensor assembly (160) coupled to the charge controller, the arc sensor assembly including a diversity antenna (162) for detecting an arc signature on the power line due to an arcing event, the diversity antenna transmitting an arc output signal to the charge controller based on detection of the arc signature; A vehicle charging system (10) comprising:

2. 2. The vehicle charging system of claim 1, wherein the diversity antenna includes a first diversity antenna element and a second diversity antenna element, the first diversity antenna element and the second diversity antenna element operating in different receive modes.

3. 2. The vehicle charging system of claim 1, wherein the diversity antenna includes a first diversity antenna element and a second diversity antenna element, the first diversity antenna element including a patch antenna element operating in an e-field receive mode, and the second diversity antenna element including a coil antenna element operating in an h-field receive mode.

4. The vehicle charging system (10) of claim 1, wherein the diversity antenna (162) provides at least one of position diversity, radiation pattern diversity, polarization diversity, frequency diversity, and mode diversity.

5. 2. The vehicle charging system of claim 1, wherein the diversity antenna includes a first diversity antenna element and a second diversity antenna element, the first diversity antenna element being positioned proximate the power line at the electric vehicle and the second diversity antenna element being positioned away from the power line at the electric vehicle.

6. 2. The vehicle charging system of claim 1, wherein the arc sensor assembly includes a noise blanker configured to block signals received by the diversity antenna.

7. 7. The vehicle charging system of claim 6, wherein the noise blanker is configured to block the signal received by the diversity antenna when an external trigger event is detected from a source other than the vehicle charging system.

8. 2. The vehicle charging system of claim 1, wherein the diversity antenna includes a primary diversity antenna element proximate to and closely coupled to the power lines for detecting electromagnetic fields from vehicle charging signals transmitted along the power lines, and the diversity antenna includes a secondary diversity antenna element remote from the power lines for detecting external electromagnetic fields from external signals generated from a source other than the vehicle charging system, the arc sensor assembly includes a receiver that receives signals from the primary diversity antenna element, and the arc sensor assembly includes a noise blanker configured to block signals at the receiver based on the external signals from the secondary diversity antenna element.

9. 9. The vehicle charging system of claim 8, wherein the secondary diversity antenna element is positioned proximate to a motor inverter of the electric vehicle and configured to detect switching transients caused by inverter operation, and the noise blanker is configured to block signals at the receiver based on the switching transients detected by the secondary diversity antenna element.

10. 10. The vehicle charging system of claim 1, wherein the arc sensor assembly includes a signal processing device configured for beam steering detection to determine a direction of arrival of a signal at the diversity antenna.

11. 2. The vehicle charging system of claim 1, wherein the diversity antenna includes a first diversity antenna element and a second diversity antenna element, and the arc sensor assembly includes a signal processing device that processes signals from the first diversity antenna element and the second diversity antenna element, the signal processing device configured for diversity switching to select the first diversity antenna element or the second diversity antenna element having the least noise.

12. 2. The vehicle charging system of claim 1, wherein the diversity antenna includes a first diversity antenna element and a second diversity antenna element, the first diversity antenna element being an omnidirectional antenna element and the second diversity antenna element being a directional antenna focused in a direction of the power line.

13. The vehicle charging system (10) of claim 1, wherein the diversity antenna (162) includes three or more diversity antenna elements (170, 172).

14. 10. The vehicle charging system of claim 1, wherein the arc sensor assembly includes a signal processing device configured for phase-coherent summation and analysis of different combinations of signals from the diversity antennas.

15. The vehicle charging system (10) of claim 1, wherein the arc sensor assembly (160) monitors arc signals in at least one of the power conductor (105) and the charging terminal (107).

16. The vehicle charging system (10) of claim 1, wherein the arc sensor assembly (160) is disposed in the interior cavity (134) of the housing (102).

17. The vehicle charging system (10) of claim 1, wherein the arc sensor assembly (160) is disposed in a battery distribution unit of a battery system (12) of the electric vehicle (14).

18. 2. The vehicle charging system of claim 1, wherein the charge controller interrupts power supplied to the charging terminals when the arcing event is detected.

19. 2. The vehicle charging system (10) of claim 1, wherein the housing (102) is a charging connector housing configured to be removably coupled to a charging inlet housing of the charging component (40) of the electric vehicle (14), and the charging terminal (107) is a socket terminal configured to mate with a pin terminal of the charging component and supply power to the electric vehicle via the pin terminal.

20. 2. The vehicle charging system of claim 1, wherein the housing is a charging inlet housing configured to be attached to the electric vehicle and to receive a charging connector housing of the charging component, and the charging terminal includes a pin configured to mate with a socket terminal of the charging component to receive power from the charging component.

21. A vehicle charging system (10) for an electric vehicle (14), comprising: a housing (102) having a mating end (210) for mating with a charging component (40) for the electric vehicle, the housing including an interior cavity (134); charging terminals (107) carried by the housing in the internal cavity, each charging terminal including a mating end for mating with the charging component, the charging terminals connected to corresponding power conductors (105) to form power lines (166, 168); a charging controller (140) for controlling charging of vehicles along the power line; an arc sensor assembly (160) coupled to the charge controller, the arc sensor assembly including a diversity antenna (162) for detecting an arc signature on the power line due to an arcing event, the diversity antenna including a primary diversity antenna element (170) for detecting a first signal and a secondary diversity antenna element (172) for detecting a second signal, the arc sensor assembly including a receiver for receiving signals from at least one of the primary diversity antenna element and the secondary diversity antenna element, the arc sensor assembly including a noise blanker operatively coupled to the receiver to control the signal received by the receiver, and the arc sensor assembly transmitting an arc output signal to the charge controller based on the signal received by the receiver; A vehicle charging system (10) comprising:

22. 22. The vehicle charging system of claim 21, wherein the primary diversity antenna element is closely coupled to and in proximity to the power lines to detect electromagnetic fields from vehicle charging signals transmitted along the power lines, the secondary diversity antenna element is positioned away from the power lines to detect external electromagnetic fields from external signals generated from sources other than the vehicle charging system, and the noise blanker is configured to block signals at the receiver based on the external signals from the secondary diversity antenna element.

23. A charging inlet assembly for an electric vehicle (14), comprising: a housing (102) extending between a front and a rear, the housing having a chamber at the rear, the housing having a power connector at the front for receiving a charging connector, the power connector including a terminal channel between the front and rear; charging terminals (107) received in the corresponding terminal channels, each of the charging terminals including a mating pin and a terminal end opposite the mating pin, the mating pin positioned in the corresponding terminal channel to mate with the charging connector, the terminal end positioned in the chamber at the rear of the housing, and connected to a power conductor to form a power line (166, 168); a charging controller (140) for controlling vehicle charging along the power line during a charging operation; an arc sensor assembly (160) coupled to the charge controller, the arc sensor assembly including a diversity antenna for detecting an arc signature on the power line due to an arcing event, the diversity antenna transmitting an arc output signal to the charge controller based on detection of the arc signature; 1. A charging inlet assembly comprising:

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