CCS Charger Connector Using AC Pins for Fast Charging Communication
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Solution Overview
Problem
Existing CCS charging systems are slow and unreliable for rapid and reliable charging processes, particularly in applications requiring quick communication and power delivery, such as in motorsports.
Innovation Solution
Repurpose AC pin sockets in CCS sockets for communication purposes, using first and second communication pins to enhance reliability and reduce signal loss, and utilize positive and negative DC pins for charging, while maintaining compatibility with CCS standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power line communication (PLC) using control pilot pin socket is used for charging control, then charging functionality is achieved, but communication initialization is slow and reliability is reduced
Solution Approach 1:
The patent repurposes the AC pin sockets (L1, L2, L3, neutral) to serve dual functions: they can carry AC power during standard charging operations and simultaneously serve as communication channels during DC charging when AC power is not required. This multi-functionality eliminates the need for dedicated communication pins, enabling faster and more reliable communication while maintaining compatibility with existing CCS socket infrastructure.
Solution Approach 2:
The patent changes the functional parameter of the AC pin sockets from exclusively power transmission to allowing both power transmission and data communication. By modifying the electrical signal characteristics on these existing pins (using differential signaling or other communication protocols over the power lines), the system achieves rapid communication initialization without adding new physical components.
2Reliability
If AC pin sockets are repurposed for communication purposes, then communication reliability is improved, but AC charging capability is lost
Solution Approach 1:
The patent implements dynamic pin assignment where the function of each pin is determined at runtime based on the charging mode. During DC charging, the AC pins are dynamically reassigned for communication purposes. During AC charging, the system detects this mode and reassigns the pins back to their traditional power transmission function. This dynamic reconfiguration allows the same hardware to support multiple charging modes without physical modification.
Solution Approach 2:
The patent segments the charging protocol into distinct phases: a communication initialization phase using the repurposed AC pins for rapid handshaking and parameter exchange, followed by a charging execution phase where the system transitions to appropriate power delivery. This segmentation allows the communication function to be temporarily activated only when needed, preserving AC charging capability for other operations.
3Productivity
If conventional CCS protocol steps (payment authorization and charger parameter discovery) are reduced or eliminated, then charging speed is improved, but protocol compatibility is compromised
Solution Approach 1:
The patent performs critical communication and parameter exchange actions during the initial connection phase using the repurposed AC pins for communication. By completing payment authorization, vehicle identification, and charger parameter discovery before the charging session officially begins, the system eliminates the need for these steps during the charging process itself. This preliminary action reduces protocol complexity and accelerates charging start-up while maintaining all necessary safety and compatibility checks.
Data Source
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AI summary
Disclosed is an electrical charger connector (3) comprising a charger plug (17) having connection pins (81) comprising first (87) and second (89) communication pins. The first and second communication pins are arranged to cooperatively engage respective first (31) and second (33) communication pin sockets of a charging socket (11), to thereby create connections for the sending and/or receiving of at least one communication signal between a charger control system (13) of an electrical charger (5) and a rechargeable energy store control system (9) of an electrically powered device (1). The first (31) and second (33) communication pin sockets correspond in position and form with respective alternating current, AC, pin sockets of a combined charging system, CCS, socket.