Vehicle charging system for electric vehicles with arc detection

Abstract

To provide a vehicle charging system for an electric vehicle with an arc detection function.SOLUTION: In a vehicle charging system 10 used for charging a battery system 12 of a vehicle 14 such as an electric vehicle or a hybrid electric vehicle, a first charging component 20 including a charge controller 30 for controlling vehicle charging and a second charging component 40 are coupled to each other. First charging component 20 includes a charging sensor assembly 34 coupled to charge controller 30. The charge sensor assembly monitors a state of charge of the vehicle charging system along the power transmission line, generates a charge output signal, transmits the charge output signal to the charge controller, detects an arc signature from an arc event, and generates an arc output signal to the charge controller, based on which the charge controller generates a primary control output for performing a primary protective operation including stopping the charging operation and a secondary control output for performing a secondary protective operation.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This application claims the benefit of U.S. Application No. 63 / 665,372, 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. The charging terminals include mating ends for mating with the charging component. The charging terminals are connected to 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 charge controller includes a charge sensor assembly coupled to the charge controller. The charge sensor assembly monitors a state of charge of the vehicle charging system along the power transmission line and generates a charge output signal. The charge sensor assembly transmits the charge output signal to the charge controller. The charge sensor assembly is configured to detect an arc signature from the arc event and generate an arc output signal to the charge controller. The charge controller generates a primary control output for taking a primary protective action, including terminating charging operation, based on the arc output signal associated with the arc event. The charge controller generates a secondary control output for taking a secondary protective action, based on the arc output signal associated with the arc event.

[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. 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 may be controlled based on the temperature measurements of temperature sensor 32. Temperature sensor 32 may 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.

[0012] In the exemplary embodiment, first charging component 20 includes a charge sensor assembly 34 coupled to charge controller 30. Charge sensor assembly 34 monitors the state of charge of a vehicle charging system along the power line and generates a charge output signal. Charge sensor assembly 34 transmits the charge output signal to charge controller 30. Charge sensor assembly 34 is configured to detect an arc signature from an arcing event and generate an arc output signal to charge controller 30. In the exemplary embodiment, charge controller 30 generates a primary control output for taking a primary protective action, including terminating charging operations, based on the arc output signal associated with the arcing event. In the exemplary embodiment, charge controller 30 generates a secondary control output for taking a secondary protective action based on the arc output signal associated with the arcing event.

[0013] In an exemplary embodiment, charge sensor assembly 34 includes one or more sensors that monitor the charging state. For example, charge sensor assembly 34 may include one or more temperature sensors, such as temperature sensor 32. Charge sensor assembly 34 may include one or more optical sensors, such as a photodetector, configured to detect optical output from an arcing event. Charge sensor assembly 34 may include one or more sensor antennas for detecting the electromagnetic field of signals transmitted along the power line, which may be used to detect an arc signature during an arcing event. Charge sensor assembly 34 may include one or more current sensors, such as current transformers, operably coupled to charge controller 30 to monitor current transmitted along the power line, e.g., at charging terminals 26 and / or along power conductors 28, within first charging component 20.

[0014] The charge sensor assembly 34 is operably coupled to the charge controller 30 to control vehicle charging, for example, based on the monitored signal and / or based on detection of an arcing event by the charge sensor assembly 34. For example, when an arcing event is detected, the primary protective action taken by the charge controller 30 is to immediately interrupt the power supply to stop the charging process and extinguish the arc. For example, the charge controller 30 can be operably coupled to a charge disconnection device, such as a pyro-fuse, contactor, or solid-state relay, configured to stop the charging current in the power line. The primary control output is transmitted to the charge disconnection device to stop the charging operation. In an exemplary embodiment, the charge controller 30 can communicate with the second charging component 40 to, for example, interrupt the power supply to stop the charging process. Such redundant action allows both charging components to stop charging operations as a primary protective action.

[0015] In an exemplary embodiment, when an arc event is detected, one or more secondary protection actions are taken by the charge controller. For example, the secondary control output may include recording the arc event in a database. The database may be in the vehicle, the charging station, a cloud-based server or database, or the like. Based on the database, the system may track component life and system behavior across a network of infrastructure components. Recording the arc event may include sending the arc information to the database. For example, the arc information may be an arc output signal from an arc sensor assembly, such as a sensor reading, a time the arc event occurred, and an action taken by the system based on the arc event. The system can identify live components for further inspection or replacement based on the recorded arcing event. The system can identify further actions that can be taken based on the recorded arcing event, which actions can depend on the severity of the arcing event.

[0016] The secondary control output may include sending the secondary control output to charging component 40 to control the charging operation of charging component 40. For example, a control signal may be transmitted between the vehicle and the charging station to control the operation of one or both of the charging components upon detection of an arcing event.

[0017] The secondary control output can include transmitting a warning signal to an operator of the vehicle. The warning signal can be at least one of a visual signal, an audible signal, a tactile signal, and an olfactory signal. The warning signal can be transmitted to the operator of the vehicle to warn the operator to exit the vehicle and inspect components for damage or potential fire.

[0018] The charge sensor assembly 34 (and / or components of the charge sensor assembly 34) may be provided in various locations within the vehicle charging system 10. For example, the charge sensor assembly 34 may be located within or on the first charging part 20. In various other embodiments, the charge sensor assembly 34 may be located within or on the vehicle 14, such as within or on the battery system 12. For example, the charge sensor assembly 34 may be incorporated into a battery distribution unit (BDU) or other component of the battery system 12.

[0019] 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.

[0020] 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.

[0021] 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 may be controlled based on the temperature measurements of temperature sensor 52. Temperature sensor 52 may 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.

[0022] In the exemplary embodiment, second charging component 40 includes a charge sensor assembly 54 coupled to charge controller 50. Charge sensor assembly 54 monitors the charging status of vehicle charging systems (e.g., charging plugs and / or charging stations) along the power line and generates a charge output signal. Charge sensor assembly 54 transmits the charge output signal to charge controller 50. Charge sensor assembly 54 is configured to detect an arc signature from an arcing event and generate an arc output signal to charge controller 50. In the exemplary embodiment, charge controller 50 generates a primary control output for taking a primary protective action, including terminating charging operations, based on the arc output signal associated with the arcing event. In the exemplary embodiment, charge controller 50 generates a secondary control output for taking a secondary protective action, based on the arc output signal associated with the arcing event.

[0023] In an exemplary embodiment, charge sensor assembly 54 includes one or more sensors that monitor the charging state. For example, charge sensor assembly 54 may include one or more temperature sensors, such as temperature sensor 52. Charge sensor assembly 54 may include one or more optical sensors, such as a photodetector, configured to detect optical output from an arcing event. Charge sensor assembly 54 may include one or more sensor antennas for detecting the electromagnetic field of signals transmitted along the power line, which may be used to detect an arc signature during an arcing event. Charge sensor assembly 54 may include one or more current sensors, such as current transformers, operably coupled to charge controller 50 to monitor current transmitted along the power line, e.g., at charging terminals 46 and / or along power conductors 48, within second charging component 40.

[0024] The charge sensor assembly 54 is operably coupled to the charge controller 50 to control vehicle charging, for example, based on the monitored signal and / or based on detection of an arcing event by the charge sensor assembly 54. For example, when an arcing event is detected, the primary protective action taken by the charge controller 50 is to immediately interrupt the power supply to stop the charging process and extinguish the arc. For example, the charge controller 50 can be operably coupled to a charge disconnection device, such as a pyro-fuse, contactor, or solid-state relay, configured to stop the charging current in the power line. The primary control output is transmitted to the charge disconnection device to stop the charging operation. In an exemplary embodiment, the charge controller 50 can communicate with the first charging component 20 to, for example, interrupt the power supply to stop the charging process. Such redundant action allows both charging components to stop the charging operation as a primary protective action.

[0025] In an exemplary embodiment, when an arc event is detected, one or more secondary protection actions are taken by the charge controller. For example, the secondary control output may include recording the arc event in a database. The database may be in the vehicle, the charging station, a cloud-based server or database, or the like. Based on the database, the system may track component life and system behavior across a network of infrastructure components. Recording the arc event may include sending the arc information to the database. For example, the arc information may be an arc output signal from an arc sensor assembly, such as a sensor reading, a time the arc event occurred, and an action taken by the system based on the arc event. The system can identify live components for further inspection or replacement based on the recorded arcing event. The system can identify further actions that can be taken based on the recorded arcing event, which actions can depend on the severity of the arcing event.

[0026] The secondary control output may include sending the secondary control output to charging component 40 to control the charging operation of charging component 40. For example, a control signal may be transmitted between the vehicle and the charging station to control the operation of one or both of the charging components upon detection of an arcing event.

[0027] The secondary control output can include transmitting a warning signal to an operator of the vehicle. The warning signal can be at least one of a visual signal, an audible signal, a tactile signal, and an olfactory signal. The warning signal can be transmitted to the operator of the vehicle to warn the operator to exit the vehicle and inspect components for damage or potential fire.

[0028] Charge sensor assembly 54 (and / or components of charge sensor assembly 54) may be provided in various locations within vehicle charging system 10. For example, charge sensor assembly 54 may be located within or on second charging component 40. For example, charge sensor assembly 54 may be located within or on a charging plug. In various other embodiments, charge sensor assembly 54 may be located within or on power source 16, for example, within or on a charging station.

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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, e.g., a pair of DC charging terminals 108, in DC charging portion 104. DC charging terminals 108 are configured to be electrically connected to the 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, e.g., crimped or welded to DC charging terminals 108. In other embodiments, the DC power conductors 109 can be electrically connected to the DC charging terminals 108 through a separable interface, such as through a connector that mates with the housing 102 at the rear. The DC charging terminals 108 and the DC power conductors 109 form a power transmission line through the vehicle.

[0033] 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.

[0034] 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.

[0035] Conductors 109, 111 extend from charge 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 conductor 109 can transmit high voltage for charging the battery, and AC conductor 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 charge inlet assembly 100 and the battery system. For example, conductor 111 can transmit data related to charging start / stop, operating temperatures of power terminals 108 and / or 110, or other charging data. Conductor 111 can send a proximity signal to the battery system indicating when a charging device is mated with power connector 101 of charge inlet assembly 100.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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 may be received in an internal 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.

[0041] 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.

[0042] In the exemplary embodiment, the control assembly includes a charge sensor assembly 146 having one or more sensors 150 used to monitor the charging process and control the charging operation. The sensors 150 are used to sense the operating characteristics of components or the charging process and 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.

[0043] 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.

[0044] In various embodiments, sensor 150 includes current sensor 154. Current sensor 154 monitors the current in the power line (e.g., charging terminals 107 and power conductors 105). In an exemplary embodiment, current sensor 154 includes a current transformer or other current measurement device that measures the current in the power line. The current transformer includes a primary coil that carries the current to be measured and a secondary coil that generates a current proportional to the primary coil that is sent to a meter (e.g., a voltmeter) or other measuring instrument. However, in alternative embodiments, other types of current sensors, such as Hall-effect sensors, can be used. The Hall-effect sensor can sense current over a frequency range similar to that of the power line during an arcing event (e.g., have a sensing range similar to that of the arc signature).

[0045] In various embodiments, the sensor 150 includes one or more optical sensors 156 configured to detect light output from an arcing event. The optical sensors 156 may include a photodetector, such as a photodiode, for detecting light from the arcing event. For example, the light generated by the arcing event may be in an optical frequency range, etc. The light of an electric arc may be in a predetermined range, such as an infrared frequency range, a visible frequency range, and / or an ultraviolet frequency range. The optical detector is positioned to visually monitor the internal cavity 134, such as the terminal channel 128, to detect an arcing event near the mating interface between the charging terminals 107.

[0046] The sensor 150 can include one or more sensor antennas 158 for detecting the electromagnetic fields of signals transmitted along the power line, which can be used to detect an arc signature during an arcing event. The sensor antenna elements can be positioned proximate the power line and connected to one or more antenna circuits that process the signals from the antenna elements. In an exemplary embodiment, the antenna elements can include e-field antenna elements, b-field antenna elements, and / or h-field antenna elements. The antenna elements can measure electrostatic signals. The antenna elements can measure magnetic signals. In alternative embodiments, other types of antenna elements can be used.

[0047] Sensor 150 of charge sensor assembly 146 is coupled to charge controller 140. For example, charge sensor assembly 146 can transmit one or more outputs related to, for example, a charging operation and / or an arcing event to charge controller 140. For example, charge sensor assembly 146 can transmit a charging output signal related to the charging process, such as the temperature of the terminals, the current transmitted along the power line, etc. Charge sensor assembly 146 can transmit an arcing output signal related to the detection of an arcing event. Charge controller 140 can include a processing device, such as a microcontroller, a processor, a digital signal processor, a neural network, a frequency diplexer, etc., to process the signals. Charge controller 140 is used to control the charging operation. 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 a signal from charge sensor assembly 146 (e.g., based on the current output signal and / or based on the arc output signal).

[0048] In the exemplary embodiment, charging sensor assembly 146 is used to detect an arc signature associated with an arcing event, such as at the mating end of charging terminal 107, within charging inlet assembly 100. For example, when one or more of sensors 150 detects an arcing event (e.g., high current, light, high frequency, high temperature, etc.), charging sensor assembly 146 outputs an arc output signal to charging controller 140. The arc output signal is transmitted to charging controller 140 to control charging operations based on the detection of the arcing event.

[0049] In an exemplary embodiment, charge controller 140 generates a primary control output for taking a primary protective action, including terminating charging operation, based on an arc output signal associated with the arc event. In an exemplary embodiment, charge controller 140 generates a secondary control output for taking a secondary protective action based on an arc output signal associated with the arc event. Different process flows and protective actions can be taken depending on the severity of the arc, which can be determined by the strength of the signal received by sensor 150. For example, when an arc occurs during low-power charging, a slower method of interrupting current may be appropriate. When an arc occurs during high-power charging, a faster method of interrupting current may be required.

[0050] Charge sensor assembly 146 is operably coupled to charge controller 140 to control vehicle charging, for example, based on the monitored signals and / or based on detection of an arcing event by charge sensor assembly 146. For example, when an arcing event is detected, the primary protective action taken by charge controller 140 is to immediately interrupt the power supply to stop the charging process and extinguish the arc. Current and voltage from the charging connector are immediately stopped to prevent damage to components or the vehicle. In an exemplary embodiment, charge controller 140 is operably coupled to a charge disconnect device 160, such as a pyrofuse, contactor, or solid-state relay configured to stop the charging current on the power line. Pyro fuses react quickly to interrupt current; mechanical contactors are slower but reusable; and solid state relays react quickly to interrupt current and are reusable. The primary control output is transmitted to a charge disconnect device 160 to stop charging operation.

[0051] In the exemplary embodiment, charging controller 140 includes a communication module 162 to enable communication with other components within the vehicle and / or with a charging station, for example. Communication module 162 may be a wireless communication module. In various other embodiments, communication module 162 may be a wired communication device. Communication module 162 may communicate with the charging station via communication terminals, such as a pilot pin and a proximity pin. Communication module 162 enables communication with a second charging component (e.g., a charging plug and / or a charging station) and interrupts the power supply to stop the charging process. This redundant operation allows both charging components to stop charging operations as a primary protective action. By communicating signals related to an arc event to both components of the charging system, a cooperative current interruption process can be achieved, improving arc detection reliability and fault redundancy. Both systems can operate independently based on data or signals related to, for example, an arc event, that are shared between the components during the charging process.

[0052] In an exemplary embodiment, when an arcing event is detected, one or more secondary protection actions are taken by charge controller 140. For example, the secondary control output may include recording the arcing event in a database. The database may be in the vehicle, the charging station, a cloud-based server or database, etc. Based on the database, the system may track component life and system behavior across a network of infrastructure components. Recording the arcing event may include sending the arc information to the database. For example, the arc information may be an arc output signal from arc sensor assembly 146, such as a sensor reading, a time the arcing event occurred, and an action taken by the system based on the arcing event. The system may identify or flag live components for further inspection or replacement based on the recorded arcing event. The system may identify further actions that can be taken based on the recorded arcing event, which may depend on the severity of the arcing event.

[0053] The secondary control output may include sending the secondary control output to other charging components (e.g., a charging plug and / or a charging station) to control the charging operation of the charging components. For example, a control signal may be transmitted between the vehicle and the charging station to control the operation of one or both of the charging components upon detection of an arcing event.

[0054] The secondary control output may include transmitting a warning signal to an operator of the vehicle. The warning signal may be at least one of a visual signal, an audible signal, a tactile signal, and an olfactory signal. The warning signal may be transmitted by the communications module 162. The warning signal may be transmitted to the operator of the vehicle to warn the operator to exit the vehicle and inspect components for damage or potential fire.

[0055] In the exemplary embodiment, charging controller 140 includes a control device 144 for controlling one or more functions of the vehicle charging system. Control device 144 may include software and / or hardware for processing signals that control charging operations. Control device 144 may receive signals and / or inputs, such as from charging sensor assembly 146. Control device 144 may process and / or analyze the signals / inputs to determine and / or generate one or more outputs, such as a primary control output and / or a secondary control output.

[0056] In an exemplary embodiment, control device 144 or other component of charge controller 140 includes an envelope detector 170 that defines a signal envelope that includes an arc signature. Envelope detector 170 detects an arc event when the arc signature is present in the signal envelope. Envelope detector 170 may include a series of amplifiers that limit the bandwidth of the input signal to a region typically associated with arcing (e.g., 300 kHz to 3 MHz) and then apply a threshold detector to detect the presence or absence of the signal. Envelope detector 170 may include one or more filters, such as a low-pass filter and / or a high-pass filter.

[0057] In an exemplary embodiment, control device 144 or other components of charge controller 140 include anomaly detector 172 configured to detect anomalous sensor readings from arc sensor assembly 146. For example, during an arcing event, sensor readings from one or more of sensors 150 may be affected, leading to anomalous sensor readings. For example, a temperature sensor may read a negative temperature. Rather than discarding or rejecting such anomalous sensor readings as unreliable, anomaly detector 172 treats the anomalous sensor readings as a positive arc signature to charge controller 140. Charge controller 140 can generate a primary control output and a secondary control output based on the anomalous sensor readings.

[0058] In an exemplary embodiment, the control device 144 or other components of the charge controller 140 include a digital signal processor 174 configured to process the arc output signal. The digital signal processor 174 is configured to analyze the arc output signal to identify when an arc event is occurring. The digital signal processor 174 is configured to generate primary and secondary control outputs based on the processed arc output signal. The digital signal processor 174 provides digital equivalent signals that are sampled, digitized, and numerically manipulated to provide functions such as filtering, detection, and spectrograms. The digital signal processor 174 processes the signals using algorithms. The algorithms are immune to drift and component tolerance variations. Parameters of the algorithms can be dynamically changed under digital control. For arc detection, key parameters such as the detection algorithm or filter bandpass can be dynamically changed as needed to suit specific stages of the charging cycle. The control device or other components of the charge controller 140 can include a neural network or artificial intelligence structure that can function as an envelope detector, anomaly detector, or sensor fusion device to combine signals from multiple sensors and generate an arc / no-arc output decision. Neural networks can improve detection quality by improving detection rates, false positive and negative detection rates, and by fusing data and inputs from multiple sensors in a diversity manner.

[0059] 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.

[0060] 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 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 terminals 107. Current sensor 154 monitors the current transmitted along the power line (e.g., along charging terminals 107). In an exemplary embodiment, current sensor 154 monitors the current in the power line for arcing events, such as at mating end 66 of charging terminal 62 or the mating end of charging terminal 107. Optical sensor 156 monitors for arcing events near the mating interface between charging terminals 62, 107. Sensor antenna 158 monitors the electromagnetic field along the power line.

[0061] 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 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.

[0062] 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.

[0063] The current sensor 154 monitors the current along the power line. By monitoring the current, the current sensor 154 can detect high-frequency spikes in the current along the power line during an arcing event. Thus, the current sensor 154 detects an arcing event in the charging inlet assembly 100. In various embodiments, the current sensor 154 monitors an arc noise signature to detect the arcing event. In an exemplary embodiment, the current sensor 154 monitors an arc noise signature to detect the arcing event. For example, the arc noise is generated by the arcing event as a result of the arc energy, such as in the radio frequency range. The characteristic noise signature of an electric arc may be in a predetermined range, such as from 1 kHz to 100 GHz. The characteristic noise signature of an electric arc may be in a more specific range, such as 100-500 kHz. Current sensor 154 detects the stochastic energy or noise signature produced by the electric arc. In an exemplary embodiment, current sensor 154 can monitor the power line of charging inlet assembly 100 to detect an arc noise signature on the power line corresponding to an arcing event. Current sensor 154 can monitor the current along charging terminal 107 and / or power conductor 109.

[0064] 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. Current sensor 154 and / or sensor antenna 158 monitor the arc noise signature of the electrical circuit to detect the arc noise signature conducted in the power line when an arc fault occurs. Charge controller 140 can include an internal processor of the ACFI device that distinguishes between normal operation and dangerous arcing and automatically opens the circuit to reduce the risk of damage to the system.

[0065] In various embodiments, current sensor 154 and / or sensor antenna 158 are connected to other wiring or circuitry to detect the arc noise signature. Current sensor 154 and / or sensor antenna 158 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, current sensor 154 and / or sensor antenna 158 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. Current sensor 154 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.

[0066] In an exemplary embodiment, current sensor 154 and / or sensor antenna 158 are electrically coupled to the power line at or near cable connector 202 at rear 212 of charging terminal 107. Current sensor 154 and / or sensor antenna 158 can be coupled to cable connector 202 or conductor 109. In various embodiments, current sensor 154 can include a current transformer around power conductor 109 to monitor an electrical signature along conductor 109. In various other embodiments, current sensor 154 can include a Hall sensor adjacent conductor 109 or cable connector 202 to monitor an electrical signature along the electrical circuit. In various embodiments, current sensor 154 includes an induction coil to monitor an electrical signature along the electrical circuit. The induction coil can be positioned on or near the cable connector 202 or the conductor 109. The induction coil can be provided on a circuit board, for example, the circuit board 142, or a separate circuit board, such as the circuit board for the temperature sensor system. In various embodiments, the induction coil is coarsely regulated using a capacitor. The current sensor 154 can include insulation from the power circuit, for example, from the conductor 109 or the conductor of the cable connector 202, to prevent damage to the current sensor 154. For example, the current transformer, Hall sensor, and / or induction coil can have electrical insulation from the conductors carrying the charging current. The electrical insulation can be provided by an appropriate DC-blocking capacitor to isolate the component from the charging current conductor.

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); a charging terminal (107) held by the housing in the internal cavity, the charging terminal including a mating end (210) for mating with the live part, the charging terminal being connected to a power conductor (105) to form a power transmission line; a charge controller (140) for controlling vehicle charging along the power line, the charge controller including a charge sensor assembly (146) coupled to the charge controller; a charge controller (140), wherein the charge sensor assembly monitors a state of charge of the vehicle charging system along the power line and generates a charge output signal, the charge sensor assembly transmits the charge output signal to the charge controller, and the charge sensor assembly is configured to detect an arc signature from an arcing event and generate an arc output signal to the charge controller; Equipped with the charge controller generates a primary control output for taking a primary protective action, including terminating charging operations, based on the arc output signal related to the arc event; The charge controller generates a secondary control output for performing a secondary protection action based on the arc output signal related to the arc event.

2. The vehicle charging system (10) of claim 1, wherein the secondary control output includes recording the arcing event in a database.

3. 3. The vehicle charging system of claim 2, wherein the recording of the arc event includes sending arc information to the database, the arc information including the arc output signal from the arc sensor assembly.

4. 2. The vehicle charging system (10) of claim 1, wherein the secondary control output includes sending the secondary control output to the charging component (40) to control the charging operation of the charging component (40).

5. 2. The vehicle charging system (10) of claim 1, wherein the secondary control output includes transmitting a warning signal to an operator of the vehicle (14), the warning signal being at least one of a visual signal, an audible signal, a tactile signal, and an olfactory signal.

6. 2. The vehicle charging system (10) of claim 1, further comprising a charge disconnection device (160), wherein the charge controller (140) is operably coupled to the charge disconnection device, and the primary control output is transmitted to the charge disconnection device to stop the charging operation.

7. 7. The vehicle charging system of claim 6, wherein the charge disconnect device includes one of a pyro-fuse, a contactor, or a solid-state relay configured to terminate charging current on the power line.

8. 2. The vehicle charging system of claim 1, wherein the arc sensor assembly includes at least one of a temperature sensor, a current sensor, a light sensor, and an arc detection antenna for detecting the arc signature.

9. 2. The vehicle charging system of claim 1, wherein the charge controller includes an envelope detector that defines a signal envelope that includes the arc signature, and the envelope detector detects the arc event when the arc signature is in the signal envelope.

10. 2. The vehicle charging system of claim 1, wherein the charge controller includes an anomaly detector configured to detect an anomalous sensor reading from the arc sensor assembly, the anomaly detector treating the anomalous sensor reading as a positive arc signature to a charge controller and generating the primary control output and the secondary control output based on the anomalous sensor reading.

11. 2. The vehicle charging system of claim 1, wherein the charge controller includes a digital signal processor configured to process the arc output signal, the digital signal processor configured to analyze the arc output signal to identify when the arc event is occurring, and configured to generate the primary control output and the secondary control output based on the processed arc output signal.

12. The vehicle charging system (10) of claim 1, wherein the charge controller (140) is disposed in the interior cavity (134) of the housing (102).

13. The vehicle charging system (10) of claim 1, wherein the charge controller (140) is located in a battery distribution unit of a battery system (12) of the electric vehicle (14).

14. 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 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 vehicle via the pin terminal.

15. 2. The vehicle charging system (10) of claim 1, wherein the housing (102) is a charging inlet housing configured to be attached to the vehicle (14) and to receive a charging connector housing of the charging component (40), and the charging terminal (107) includes pins configured to mate with socket terminals of the charging component to receive power from the charging component.

16. 1. A method of operating a vehicle charging system, comprising: The vehicle charging system includes a housing (102) having a mating end (210) for mating with a charging component (40) for an electric vehicle (14), and a charging terminal (107) carried by the housing, the charging terminal (107) including a mating end for mating with the charging component and connected to a power conductor (105) to form a transmission line, the vehicle charging system includes a charge controller (140) for controlling vehicle charging along the transmission line, the charge controller including a charge sensor assembly (146) coupled to the charge controller, The method comprises: - monitoring a state of charge of the vehicle charging system along the power line using the charge sensor assembly; - generating a charge output signal at the charge sensor assembly and transmitting the charge output signal to the charge controller; - detecting an arc signature from an arcing event along the power line with the charge sensor assembly; - generating an arc output signal at the charge sensor assembly and transmitting the arc output signal to the charge controller; generating a primary control output at the charge controller based on the arc output signal associated with the arc event to take a primary protective action, including terminating charging operation; generating a secondary control output at the charge controller based on the arc output signal associated with the arc event to perform a secondary protection action; A method comprising:

17. 17. The method of claim 16, wherein generating a secondary control output includes recording the arcing event in a database.

18. 17. The method of claim 16, wherein generating a secondary control output includes sending the secondary control output to the charging component (40) to control the charging operation of the charging component (40).

19. 17. The method of claim 16, wherein generating a secondary control output includes transmitting a warning signal to an operator of the vehicle, the warning signal being at least one of a visual signal, an audible signal, a tactile signal, and an olfactory signal.

20. 17. The method of claim 16, wherein the vehicle charging system comprises a charge disconnection device operably coupled to the charge controller (140), and wherein generating a primary control output includes transmitting the primary control output to the charge disconnection device to stop the charging operation.

21. 17. The method of claim 16, wherein the charge controller includes an envelope detector that defines a signal envelope that includes the arc signature, and wherein generating the arc output signal at the charge sensor assembly includes detecting the arc event using the envelope detector when the arc signature is in the signal envelope.

22. 17. The method of claim 16, wherein the charge controller includes an anomaly detector, and wherein generating the arc output signal at the charge sensor assembly includes detecting an anomalous sensor reading from the arc sensor assembly and operating the anomaly detector to treat the anomalous sensor reading as a positive arc signature, and wherein generating the primary control output and generating the secondary control output are based on the anomalous sensor reading.

23. 17. The method of claim 16, wherein the charge controller includes a digital signal processor, the method further including processing the arc output signal with the digital signal processor and analyzing the arc output signal with the digital signal processor to identify when the arc event is occurring, and wherein generating the primary control output and generating the secondary control output are based on the processed arc output signal.

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