Smart ev charging handle

Abstract

The EV charger handle includes a handle housing defining an interior volume and a handle plug having a plurality of terminal pins, an EV charging cable including a plurality of conductor wires and extending into the interior volume to respectively connect the plurality of conductor wires to the plurality of terminal pins to transmit a power signal to an EV connected to the handle plug, a handle logic controller disposed within the interior volume and connected at least one of the plurality of conductor wires to receive power, and one or more sensors disposed within the interior volume in electronic communication with the handle logic controller. The handle logic controller is configured to transmit a communication signal to a charger logic controller via the EV charging cable based on feedback received from the one or more sensors.

Description

SMART EV CHARGING HANDLECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to the provisional patent application filed September 24, 2023, and assigned U.S. App. No. 63 / 540,106, the entire disclosure of which is hereby incorporated by reference.FIELD OF THE DISCLOSURE

[0002] This disclosure relates to charging systems for electric vehicles (EVs) and, more particularly, to charging handles used for connected charging systems to EVs.BACKGROUND OF THE DISCLOSURE

[0003] Charging handles in the current electric vehicle (EV) charging landscape are typically not considered to be intelligent, or even logic-bearing devices. Up to this point in the EV adoption landscape, there has not been developed a clear methodology to allow for this, or the need identified. Many EV charger and electric vehicle supply equipment (EVSE) manufacturers consider this component as a commodity, and do not invest time or resources in their refinement or further development. However, there is opportunity in developing the handle plug into a “smart,” or logic-bearing device, such that it enables advanced user input and feedback, as well as provides a platform for sensing, both for reliability and operations, but also critical safety applications where a response to potential damage or environmental effects could save lives or prevent injury.

[0004] Typically only 5 to 7 conductors are used in level 2 alternating current (AC) Electric Vehicle (EV) charging applications, which can include a control pilot (CP), proximity pilot (PP), neutral (N), protective earth (PE), and one or more AC power (LI, L2, L3). Five conductors are used in the single-phase application (e.g., LI, L2, PE, PP, CP), and seven conductors are used in the 3-phase applications (e.g., LI, L2, L3, N, PE, PP, CP). In Level 3 Direct Current Fast Charging (DCFC), a similar number of conductors are used. Increasing the number of conductors can add cost and complexity to the cable, which can make the user experience of charging more difficult, as there is an increase in the diameter, stiffness, and weight of the cable as more conductors are added. This can be especially pronounced in DCFC, where additional features may exist in the cable such as fluid or gashoses or channels for active cooling. Therefore, what is needed is an improved EV charging handle with communication capabilities.BRIEF SUMMARY OF THE DISCLOSURE

[0005] An embodiment of the present disclosure provides a electric vehicle (EV) charger handle. The EV charger handle may comprise a handle housing defining an interior volume and a handle plug having a plurality of terminal pins. The EV charger handle may further comprise an EV charging cable comprising a plurality of conductor wires. The EV charging cable may extend into the interior volume to respectively connect the plurality of conductor wires to the plurality of terminal pins to transmit a power signal to an EV connected to the handle plug. The EV charger handle may further comprise a handle logic controller disposed within the interior volume. The handle logic controller may be connected to at least one of the plurality of conductor wires to receive power. The EV charger handle may further comprise one or more sensors disposed within the interior volume in electronic communication with the handle logic controller. The handle logic controller may be configured to transmit a communication signal to a charger logic controller via the EV charging cable based on feedback received from the one or more sensors.

[0006] In some embodiments, the handle logic controller may be configured to transmit the communication signal to the charger logic controller via power line communication with at least one of the plurality of conductor wires.

[0007] In some embodiments, the plurality of conductor wires may comprise at least two low power conductor wires and at least three high power conductor wires. The at least two low power conductor wires and the at least three high power conductor wires may be connected to the plurality of terminal pins to transmit the power signal to the EV connected to the handle plug.

[0008] In some embodiments, the handle logic controller may be configured to transmit the communication signal to the charger logic controller via power line communication with one of the at least two low power conductor wires.

[0009] In some embodiments, the handle logic controller may be configured to transmit the communication signal to the charger logic controller via power line communication with one of the at least three high power conductor wires.

[0010] In some embodiments, the EV charging cable may further comprise at a separate conductor wire. The handle logic controller may be configured to transmit the communication signal to the charger logic controller via power line communication with the separate conductor wire.

[0011] In some embodiments, the communication signal may be super-imposed on the power signal to produce power line communication.

[0012] In some embodiments, the EV charging cable may further comprise a fiber optic cable. The handle logic controller may be configured to transmit the communication signal to the charger logic controller via the fiber optic cable.

[0013] In some embodiments, the EV charging cable may further comprise a micro coaxial cable. The handle logic controller may be configured to transmit the communication signal to the charger logic controller via the micro coaxial cable.

[0014] In some embodiments, the one or more sensors may comprise a temperature sensor configured to collect temperature data of the plurality of terminal pins of the handle plug. The communication signal may comprise a temperature signal generated by the handle logic controller based on the temperature data. In response to receiving the temperature signal, the charger logic controller may be configured to interrupt power transmission to the EV.

[0015] In some embodiments, the one or more sensors may comprise an electrical sensor configured to collect electrical characteristic data of the plurality of terminal pins of the handle plug. The communication signal may comprise an electrical characteristic signal generated by the handle logic controller based on the electrical characteristic data.

[0016] In some embodiments, the one or more sensors may comprise a capacitive sensor configured to collect capacitive input data. The communication signal may comprise acapacitive input signal generated by the handle logic controller based on the capacitive input data.

[0017] In some embodiments, the one or more sensors may comprise an accelerometer configured to collect acceleration data of the EV charger handle. The communication signal may comprise an acceleration signal generated by the handle logic controller based on the acceleration data.

[0018] In some embodiments, the handle logic controller may be further configured to receive communication signals from the charger logic controller via the EV charging cable.

[0019] In some embodiments, the handle logic controller and the one or more sensors may be disposed on a circuit board. The one or more sensors may be configured to receive power from at least one of the plurality of conductor wires via the circuit board.

[0020] Another embodiment of the present disclosure provides an electric vehicle(EV) charging system. The EV charging system may comprise the EV charger handle of any of the embodiments of the present disclosure and an EV supply source configured to supply power. The EV charger handle may be connected to the EV supply source via the EV charging cable.DESCRIPTION OF THE DRAWINGS

[0021] For a fuller understanding of the nature and objects of the disclosure, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:FIG. l is a cutaway view of an EV charger handle according to an embodiment of the present disclosure;FIG. 2A is a block diagram of an EV charging system including an EV charger handle according to an embodiment of the present disclosure;FIG. 2B is a cross-section of an EV charging cable of the EV charging system of FIG. 2A; FIG. 3 is a block diagram of an EV charging system including an EV charger handle according to another embodiment of the present disclosure;FIG. 4A is a block diagram of an EV charging system including an EV charger handle according to another embodiment of the present disclosure;FIG. 4B is a cross-section of an EV charging cable of the EV charging system of FIG. 4A; FIG. 5A is a block diagram of an EV charging system including an EV charger handle according to another embodiment of the present disclosure;FIG. 5B is a cross-section of an EV charging cable of the EV charging system of FIG. 5 A; FIG. 6A is a block diagram of an EV charging system including an EV charger handle according to another embodiment of the present disclosure; andFIG. 6B is a cross-section of an EV charging cable of the EV charging system of FIG. 6A.DETAILED DESCRIPTION OF THE DISCLOSURE

[0022] Although claimed subject matter will be described in terms of certain embodiments, other embodiments, including embodiments that do not provide all of the benefits and features set forth herein, are also within the scope of this disclosure. Various structural, logical, process step, and electronic changes may be made without departing from the scope of the disclosure. Accordingly, the scope of the disclosure is defined only by reference to the appended claims.

[0023] An embodiment of the present disclosure provides an electric vehicle (EV) charger handle 100, as shown in FIG. 1. The EV charger handle 100 may be part of an EV charging system (e.g., as shown in FIG. 2A). The EV charging system may comprise an EV supply equipment (EVSE) 200 configured to supply power to an EV 300. For example, the EVSE 200 may comprise an EV supply source 210 configured to supply power to a battery 310 of the EV 300. The EVSE 200 may further comprise a charger logic controller 220 configured to control output of power from the EV supply source 210, and the EV 300 may further comprise an EV logic controller 320 configured to monitor power received from EV supply source 210 and manage charging of the battery 310. The EVSE 200 may further comprise a low power switching circuit 230 configured to output low power for power and communication with an EV communication circuit 330 of the EV 300. The EV charger handle 100 may be connected to the EV supply source 210 by an EV charging cable 110. When the EV charger handle 100 is connected to the EV 300, the EV supply source 210 may be configured to supply power to the battery 310 of the EV 300 via the EV charging cable 110.

[0024] The EV charging cable 110 may be an EV, EVE, EVJ, EVT, or similar high- power cable comprising a series of combined jacketed or unjacketed current carrying conductors used for EV charging. For example, the EV charging cable 110 may comprise a plurality of conductor wires 111. The plurality of conductor wires 111 may comprise at least two low power conductor wires 112 and at least three high power conductor wires 113, as shown in FIG. 2B. The low power conductor wires 112 and the high power conductor wires 113 may differ in gauge size (i.e., the high power conductor wires 113 having a larger gauge size compared to the low power conductor wires 112) and / or function. For example, in a single-phase application, the plurality of conductor wires 111 may comprise five conductors including two low power conductor wires 112 (e.g., PP and CP) and three high power conductor wires 113 (e.g., LI, L2 (or N), and PE). In three-phase applications the plurality of conductor wires 111 may comprise seven conductors including two low power conductor wires 112 (e.g., PP and CP) and five high power conductor wires 113 (e.g., LI, L2, L3, N, and PE). The plurality of conductor wires 111 may comprise additional low power conductor wires 112 and / or additional high power conductor wires 113 and is not limited herein. The EV charging cable 110 may further comprise additional wires, as further described below.

[0025] The EV charger handle 100 may comprise a handle housing 120 defining an interior volume 121 and a handle plug 122 having a plurality of terminal pins 123. The EV charging cable 110 may extend into the interior volume 121 to respectively connect the plurality of conductor wires 111 to the plurality of terminal pins 123 to transmit a power signal to the EV 300 connected to the handle plug 122. For example, the at least two low power conductor wires 112 and the least three high power conductor wires 113 may be connected to the plurality of terminal pins 123 to transmit the power signal to the battery 310 of the EV 300 connected to the handle plug 122 by a plug socket 311. The handle housing 120 may be over-molded or co-molded with the jacket of the EV charging cable 110.

[0026] The EV charger handle 100 may further comprise a handle logic controller 130. The handle logic controller 130 may be disposed in the interior volume 121 of the handle housing 120. The handle logic controller 130 may be connected to at least one of the plurality of conductor wires 111 receive power. For example, the handle logic controller 130 may receive power from one of the at least two low power conductor wires 112. In some embodiments, the handle logic controller 130 may be disposed on a circuit board 135disposed within the interior volume 121 of the handle housing 120. The circuit board 135 may include various contacts or circuits configured to transmit power received by the handle logic controller 130 to other components disposed on the circuit board 135, and to enable their communication with the handle logic controller 130, as further described below.

[0027] The EV charger handle 100 may further comprise one or more sensors 140. The one or more sensors 140 may be disposed within the interior volume 121 of the handle housing 120. The one or more sensors 140 may be in electronic communication with the handle logic controller 130. For example, the one or more sensors 140 may be configured to collect data including but not limited to temperature, voltage, current, radio frequency, electromagnetic, electric or magnetic field, capacitive, mechanical, optical or other electromagnetic spectrum information, atmospheric pressure, chemical composition, or other sensor data that could be collected from the handle housing 120, the EV charging cable 110, and plurality of terminal pins 123 connected with the EV 300. The sensor data can be used to provide value to the user, operator, municipal or utility partners of the EV charging system. The one or more sensors 140 may be disposed on the circuit board 135 to receive power.

[0028] The handle logic controller 130 may be configured to transmit a communication signal to the charger logic controller 220 of the EVSE 200. The communication signal may be transmitted via the EV charging cable 110. The communication signal may be generated by the handle logic controller 130 based on feedback received from the one or more sensors 140. Accordingly, the sensor data collected by the one or more sensors 140 may be transmitted back to the charger logic controller 220 for feedback control and identification of misuse or damage to the EV charger handle 100.

[0029] In some embodiments, the handle logic controller 130 may be configured to transmit the communication signal to the charger logic controller 220 via power line communication with at least one of the plurality of conductor wires 111 of the EV charging cable 110. Power line communication can be through single ended or differential signaling that is super-imposed on a DC or AC power signal, such that the behavior of the power signal is unchanged, but effects a communication network. This communication can use frequency shift keying, binary phase-shift keying, frequency modulation, phase modulation, and quadrature amplitude modulation, or any other signal modulation that can co-exist with the selected power system. For example, the communication signal generated by the handlelogic controller 130 may be super-imposed on the power signal generated by the EV supply source 210 or the low power switching circuit 230. Using power line communication with the existing architecture of the EV charging cable 110 may avoid an increased cost or weight in the EV charging cable 110 to establish the communication between the handle logic controller 130 and the charger logic controller 220.

[0030] In some embodiments, the handle logic controller 130 may be configured to transmit the communication signal to the charger logic controller 220 via power line communication with one of the at least two low power conductor wires 112, as shown in FIG. 2 A. In other words, the power may be supplied to the handle logic controller 130 via one of the at least two low power conductor wires 112, and the communication signal can also be super-imposed on the power signal on one of the at least two low power conductor wires 112 to enable communication with the charger logic controller 220. For example, the EV charger handle 100 may further comprise a low power transceiver 131 configured to receive power from one of the at least two low power conductor wires 112 for powering the handle logic controller 130, and the handle logic controller 130 can transmit the communication signal from the low power transceiver 131 to the charger logic controller 220 via one of the at least two low power conductor wires 112. The charger logic controller 220 may receive the communication signal via the low power switching circuit 230 and can process the communication signal to associate the signal with a logical output.

[0031] In some embodiments, the handle logic controller 130 may be configured to transmit the communication signal to the charger logic controller 220 via power line communication with one of the at least three high power conductor wires 113, as shown in FIG. 3. In other words, the power may be supplied to the handle logic controller 130 via one of the at least two low power conductor wires 112, and the communication signal can be super-imposed on the power signal on one of the at least three high power conductor wires 113 to enable communication with the charger logic controller 220. For example the EV charger handle 100 may further comprise a high power transceiver 133 connected to one of the at least three high power conductor wires 113, and the handle logic controller 130 may be configured to transmit the communication signal from the high power transceiver 133 to the charger logic controller 220 via one of the at least three high power conductor wires 113. The charger logic controller 220 may receive the communication signal via the connectionwith the EV supply source 210 and can process the communication signal to associate the signal with a logical output.

[0032] In some embodiments, the EV charging cable 110 may further comprise a fiber optic cable 114, as shown in FIG. 4 A. The fiber optic cable 114 can be single or multimode, or could be a series of fiber optic cables, providing either and half or full duplex communication. The fiber optic cable 114 may be provided in the EV charging cable 110 along with the plurality of conductor wires 111 (as shown in FIG. 4B), or may be braided in the jacket of the EV charging cable 110. The handle logic controller 130 may be configured to transmit the communication signal to the charger logic controller 220 via the fiber optic cable 114. The power may be provided to the handle logic controller 130 via one of the plurality of conductor wires 111 (e.g., one of the at least two low power conductor wires 112), and the digital communication with the charger logic controller 220 can be enabled via the fiber optic cable 114, which can be single, multi-mode, or carrier or frequency based multiplexing or other fiber optic media multiplexing. Using a thin fiber optic cable 114 or fiber optic array may not materially increase the weight or diameter of the EV charging cable 110 to establish the communication between the handle logic controller 130 and the charger logic controller 220. The EVSE 200 may comprise a fiber optic transceiver 240 configured to receive the communication signal from the fiber optic cable 114. The charger logic controller 220 may receive the communication signal via the connection with the fiber optic transceiver 240 and can process the communication signal to associate the signal with a logical output.

[0033] In some embodiments, the EV charging cable 110 may further comprise a micro coaxial cable 115, as shown in FIG. 5 A. The micro coaxial cable 115 may be provided in the EV charging cable 110 along with the plurality of conductor wires 111, as shown in FIG. 5B. The handle logic controller 130 may be configured to transmit the communication signal to the charger logic controller 220 via the micro coaxial cable 115. The power may be provided to the handle logic controller 130 via one of the plurality of conductor wires 111 (e.g., one of the at least two low power conductor wires 112), and communication with the charger logic controller 220 can be enabled via the micro coaxial cable 115. Compared to a fiber optic cable 114, the micro coaxial cable 115 may reduce the processing complexity of the communication. Using a micro coaxial cable 115 may not materially increase the weightor diameter of the EV charging cable 110 to establish the communication between the handle logic controller 130 and the charger logic controller 220. The EVSE 200 may comprise a coaxial transceiver 241 configured to receive the communication signal from the micro coaxial cable 115. The charger logic controller 220 may receive the communication signal via the connection with the coaxial transceiver 241 and can process the communication signal to associate the signal with a logical output.

[0034] In some embodiments, the EV charging cable 110 may further comprise one or more separate conductor wires 116, as shown in FIG. 6 A. The one or more separate conductor wires 116 may be provided in the EV charging cable 110 along with the plurality of conductor wires 111, as shown in FIG. 6B. The one or more separate conductor wires 116 may be distinct from the plurality of conductor wires 111 used for connection to the EV 300 for charging. For example, the one or more separate conductor wires 116 may be a dedicated conductor wire for communication between the handle logic controller 130 and the charger logic controller 220. The handle logic controller 130 may be configured to transmit the communication signal to the charger logic controller 220 via power line communication with the one or more separate conductor wires 116. The charger logic controller 220 can process the communication signal to associate the signal with a logical output. Using one or more separate conductor wires 116 for communication may reduce the processing required for power line communication compared to a super-imposed signal on one of the plurality of conductor wires 111. Other types of communication might also be used with dedicated conductors which further reduce the complexity of the communication by allowing the use of more common protocols (e.g., I2C, SPI, UART, USB, ethernet, etc.).

[0035] In some embodiments, the one or more sensors 140 may comprise a temperature sensor 141. The temperature sensor 141 may be configured to collect temperature data of the plurality of terminal pins 123 of the handle plug 122, other electrical contacts of the EV charger handle 100, or the EV charging cable 110. The communication signal may comprise a temperature signal generated by the handle logic controller 130 based on the temperature data, which can be transmitted to the charger logic controller 220. The temperature signal may allow for monitoring of the temperature of elements of the EV charger handle 100 or the EV charging cable 110 in order to sense overheating conditions that may be caused by failures of the electrical contacts. In response to receiving thetemperature signal, the charger logic controller 220 configured to interrupt or cancel power transmission to the EV 300 to prevent damage to the EV charger handle 100, the EV supply source 210, the EV 300, or potential harm to a user.

[0036] In some embodiments, the one or more sensors 140 may comprise an electrical sensor 142. The electrical sensor 142 may be configured to collect electrical characteristic data (e.g., resistance, impedance, inductance, or capacitance) of the plurality of terminal pins 123 of the handle plug 122, other electrical contacts of the EV charger handle 100, or the EV charging cable 110. The communication signal may comprise an electrical characteristic signal generated by the handle logic controller 130 based on the electrical characteristic data. With the handle logic controller 130 provided in close proximity to the electrical sensor 142 within the EV charger handle 100 (rather than the charger logic controller 220 that may be distal from the electrical sensor 142 and separated by the EV charging cable 110), the measurement accuracy of the electrical characteristic signal generated based on precise analog front end (AFE) processing of the electrical characteristic signal data may be improved. The electrical characteristic signal may allow for monitoring of the power connections of the elements of the EV charger handle 100 or the EV charging cable 110 in order to sense for degradation that would reduce performance. In response to receiving the electrical characteristic signal, the charger logic controller 220 may indicate when preventative maintenance should be performed on the EV charger handle 100 to maintain maximum uptime for the EV charging system.

[0037] In some embodiments, the one or more sensors 140 may comprise a capacitive sensor 143. The capacitive sensor 143 may be configured to collect capacitive input data. For example, the capacitive sensor 143 may be responsive to a capacitive touch user input, to the placement of the EV charger handle 100, or to damage to the handle housing 120. The communication signal may comprise a capacitive input signal generated by the handle logic controller 130 based on the capacitive input data. The capacitive input signal may be an analog signal. In response to receiving the capacitive input signal, the charger logic controller 220 may send instructions to operate automated or motorized cable management systems, provide input for locking or unlocking the plug in the electric vehicle receptacle, or other similar functionality. The capacitive input signal could also be used to identify if the EV charger handle 100 has been placed on the floor, or otherwise mishandled, to collect a feefrom users who might through negligence damage or destroy the EV charger handle 100. The capacitive input signal could also be used to detect if the EV charger handle 100 has been immersed in water. The handle logic controller 130 or the charger logic controller 220 may compare the capacitive input signal to one or more known signals to determine when the EV charger handle 100 is held in the hand of a user, in the air, in contact with a receptacle of the EV charging system, or on the ground.

[0038] In some embodiments, the one or more sensors 140 may comprise an accelerometer 144. The accelerometer 144 may be configured to collect acceleration data of the EV charger handle 100. The communication signal may comprise an acceleration signal generated by the handle logic controller 130 based on the acceleration data. In response to receiving the acceleration signal, the charger logic controller 220 can measure any potential serious impacts the EV charger handle 100, and either alert the charge station operator for abuse, which could result in a penalty fee for damages, or develop a profile of potential damage or wear which could be used operationally to track the functional life of the handle and alert the charge station operator of the need for a replacement of the EV charger handle 100. The accelerometer 144 could also be used to determine the specific orientation of the EV charger handle 100, or record the motion if the handle has been rotated in such a manner that it twists the EV charging cable 110, and communicate this back to the charger logic controller 220. When combined with the capacitive input signal, the acceleration signal may allow the charger logic controller 220 to infer when the EV charger handle 100 has been placed on the ground.

[0039] In some embodiments, the one or more sensors 140 may comprise one or more of the temperature sensor 141, the electrical sensor 142, the capacitive sensor 143, the accelerometer 144, or any combination thereof. In any case, each of the temperature sensor 141, the electrical sensor 142, the capacitive sensor 143, the accelerometer 144 may be disposed on the circuit board 135 with the handle logic controller 130 to receive power from at least one of the plurality of conductor wires 111 via the circuit board 135.

[0040] The handle logic controller 130 can be programmed a priori, at the point of power up, or continuously, such that the handle logic controller 130 can operate as a logical first-in first-out (FIFO), with commands and data being sent sequentially to be executed by the charger logic controller 220. While the communication signal is described as onedirectional from the handle logic controller 130 to the charger logic controller 220, the handle logic controller 130 may be further configured to receive communication signals from the charger logic controller 220 via the EV charging cable 110 in the same manner as those described above. Accordingly, bi-directional communication between the handle logic controller 130 and the charger logic controller 220 can be achieved, in which logical conditions can be determined by the handle logic controller 130 to direct actions to the charger logic controller 220, the user, the EV, network based services, or field service personnel.

[0041] While the communication signal is described as being transmitted by wired communication via the EV charging cable 110, the handle logic controller 130 and the charger logic controller 220 may communicate via wireless transmission (e.g., Bluetooth, WiFi, LAN, 4G, 5G, etc.) and may operate in a similar manner to that described above.

[0042] In some embodiments, the handle logic controller 130 may be further configured to provide analog or digital communication to the EV 300 via a handle communication circuit 132. The handle communication circuit 132 may establish the connection between the low power switching circuit 230 of the EVSE 200 and the EV communication circuit 330 of the EV 300. For example, the handle logic controller 130 may utilize pulse width modulation (PWM) for SAE J-1772 or IEC61851 pilot signaling, digital communication to enable ISO 15118 secure two-way communication, or other methods communication used in the field of EV charging. In this way, the handle logic controller 130 can behave as a transceiver between the charger logic controller 220 and the EV logic controller 320.

[0043] In some embodiments, the EV charger handle 100 may further comprise one or more human input and output devices such as switches, touch interfaces, dials, mechanical and optical displays (e.g., display 145), indicators, or other devices. Each of these input output devices may be in electronic communication with the handle logic controller 130 to produce feedback data input by the user or generate some alert or response. For example, the digital communication could be used to custom configure lighting characteristics of an output device, such that it could be customized by the user, or specified in their profile to provide differentiation and indication of which charger they have unlocked or had been reserved.

[0044] In some embodiments, the EV charger handle 100 may further comprise one or more fluid handling passages, machinery, or flow control devices for liquids or gasses to provide cooling to the cable, cable conductors, contacts, logic devices, or housing, wherein the fluid handling passages, machinery, or flow control devices include at least one pump, fan, heat sink, heat exchanger, heat pipe, valve, pressure sensor, or flow sensor.

[0045] The logic devices, including the handle logic controller 130, the charger logic controller 220, and the EV logic controller 320, can include a programmable processor, which is programmed in software and / or firmware to carry out the functions that are described herein, along with suitable digital and / or analog interfaces for connection to the other elements of the system. Alternatively or additionally, the logic device can include hardwired and / or programmable hardware logic circuits, which carry out at least some of the functions of the system. In practice, the logic devices may comprise multiple, interconnected units, with suitable interfaces for receiving and outputting the signals that are illustrated in the figures and are described in the text. Program code or instructions for the logic device to implement various methods and functions disclosed herein may be stored in readable storage media, such as a memory.

[0046] Although the present disclosure has been described with respect to one or more particular embodiments, it will be understood that other embodiments of the present disclosure may be made without departing from the scope of the present disclosure. Hence, the present disclosure is deemed limited only by the appended claims and the reasonable interpretation thereof.

Claims

WHAT IS CLAIMED IS:

1. An electric vehicle (EV) charger handle comprising: a handle housing defining an interior volume and a handle plug having a plurality of terminal pins; an EV charging cable comprising a plurality of conductor wires, the EV charging cable extending into the interior volume to respectively connect the plurality of conductor wires to the plurality of terminal pins to transmit a power signal to an EV connected to the handle plug; a handle logic controller disposed within the interior volume, wherein the handle logic controller is connected to at least one of the plurality of conductor wires to receive power; and one or more sensors disposed within the interior volume in electronic communication with the handle logic controller; wherein the handle logic controller is configured to transmit a communication signal to a charger logic controller via the EV charging cable based on feedback received from the one or more sensors.

2. The EV charger handle of claim 1, wherein the handle logic controller is configured to transmit the communication signal to the charger logic controller via power line communication with at least one of the plurality of conductor wires.

3. The EV charger handle of claim 2, wherein the plurality of conductor wires comprise at least two low power conductor wires and at least three high power conductor wires, the at least two low power conductor wires and the at least three high power conductor wires being connected to the plurality of terminal pins to transmit the power signal to the EV connected to the handle plug.

4. The EV charger handle of claim 3, wherein the handle logic controller is configured to transmit the communication signal to the charger logic controller via power line communication with one of the at least two low power conductor wires.

5. The EV charger handle of claim 3, wherein the handle logic controller is configured to transmit the communication signal to the charger logic controller via power line communication with one of the at least three high power conductor wires.

6. The EV charger handle of claim 3, wherein the EV charging cable further comprises at a separate conductor wire, and the handle logic controller is configured to transmit the communication signal to the charger logic controller via power line communication with the separate conductor wire.

7. The EV charger handle of claim 2, wherein the communication signal is super-imposed on the power signal to produce power line communication.

8. The EV charger handle of claim 1, wherein the EV charging cable further comprises a fiber optic cable, and the handle logic controller is configured to transmit the communication signal to the charger logic controller via the fiber optic cable.

9. The EV charger handle of claim 1, wherein the EV charging cable further comprises a micro coaxial cable, and the handle logic controller is configured to transmit the communication signal to the charger logic controller via the micro coaxial cable.

10. The EV charger handle of claim 1, wherein the one or more sensors comprises a temperature sensor configured to collect temperature data of the plurality of terminal pins of the handle plug, the communication signal comprises a temperature signal generated by the handle logic controller based on the temperature data, and in response to receiving the temperature signal, the charger logic controller is configured to interrupt power transmission to the EV.

11. The EV charger handle of claim 1, wherein the one or more sensors comprises an electrical sensor configured to collect electrical characteristic data of the plurality of terminal pins of the handle plug, and the communication signal comprises an electrical characteristic signal generated by the handle logic controller based on the electrical characteristic data.

12. The EV charger handle of claim 1, wherein the one or more sensors comprises a capacitive sensor configured to collect capacitive input data, and the communicationsignal comprises a capacitive input signal generated by the handle logic controller based on the capacitive input data.

13. The EV charger handle of claim 1, wherein the one or more sensors comprises an accelerometer configured to collect acceleration data of the EV charger handle, and the communication signal comprises an acceleration signal generated by the handle logic controller based on the acceleration data.

14. The EV charger handle of claim 1, wherein the handle logic controller is further configured to receive communication signals from the charger logic controller via the EV charging cable.

15. The EV charger handle of claim 1, wherein the handle logic controller and the one or more sensors are disposed on a circuit board, and the one or more sensors are configured to receive power from at least one of the plurality of conductor wires via the circuit board.

16. An electric vehicle (EV) charging system comprising: the EV charger handle of any one of claims 1 to 15; and an EV supply source configured to supply power, wherein the EV charger handle is connected to the EV supply source via the EV charging cable.

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