EV Charging Cable Ethernet Communication for Real-Time Data

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Solution Overview

Problem

Existing vehicle communication systems between electric charging stations and vehicles are limited by the inability to transmit individual messages or data effectively, with PWM signals being restricted and PLC communication being costly and power-intensive.

Innovation Solution

Implementing an Ethernet communication system with Time-Sensitive Networking (TSN) standards for vehicle communication, utilizing electrical communication interfaces and fallback options like PWM or PLC, to enable cost-effective and reliable transmission of individual data and messages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If PLC communication is used to transmit individual messages between charging station and vehicle, then communication capability is improved, but device cost and power consumption increase

Engineering Contradiction:

Improvecommunication capabilityVSAvoiddevice cost

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The communication system is segmented into two distinct communication units: one dedicated to PWM/status communication and another dedicated to PLC/individual message communication. This segmentation allows the system to use only the necessary communication protocol for each specific task, avoiding the need to always deploy the more complex and expensive PLC interface, thereby reducing overall device cost while maintaining full communication capability when needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The charging cable is designed with universal communication capability by integrating both PWM and PLC communication interfaces within the same physical cable structure. This multi-functionality allows the single cable to adapt to different communication requirements (status information via PWM or individual messages via PLC) without requiring separate cables or interfaces, thus improving versatility without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If PLC communication is used to transmit individual messages between charging station and vehicle, then communication capability is improved, but power consumption increases

Engineering Contradiction:

Improvecommunication capabilityVSAvoidpower consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The communication system dynamically selects between PWM and PLC protocols based on the specific communication requirements. When only status information needs to be exchanged, the system uses the low-power PWM protocol. When individual messages or complex data need to be transmitted, the system dynamically switches to PLC mode. This dynamic adaptation optimizes power consumption by avoiding unnecessary use of the higher-power PLC interface.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If PWM signal is used for vehicle communication, then device cost is reduced, but communication capability deteriorates (cannot transmit individual messages)

Engineering Contradiction:

Improvedevice costVSAvoidcommunication capability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent merges two different communication protocols (PWM and PLC) into a single integrated communication system within the charging cable. This combination allows the system to leverage the cost-effectiveness of PWM for routine status communication while simultaneously incorporating PLC capability for transmitting individual messages and complex data, thus achieving both cost reduction and enhanced communication capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If Ethernet communication with TSN standard is implemented, then real-time communication reliability is improved, but device complexity increases

Engineering Contradiction:

Improvecommunication reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The communication unit is designed with multi-functionality to support both traditional PWM/PLC protocols and the more advanced Ethernet TSN protocol. This universal design allows the system to use Ethernet TSN when high reliability and real-time performance are required (such as for safety-critical messages), while falling back to simpler PWM or PLC protocols for routine communications, thus achieving high reliability without unnecessarily increasing device complexity for all communication scenarios.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3992021B1Electrical charging station, vehicle, electric charging cable, use of the electric charging cable and system

Publication Date: 2025.12.31 WESTENERGIE AG

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AI summary

The invention relates to an electric charging station (10) for electrically charging a traction battery (27) of a vehicle (20), wherein the electric charging station (10) has a first communication interface (11) and an associated first communication unit (12), wherein the first communication unit (12) is configured for communication via Ethernet and the electric charging station (10) is configured to establish an Ethernet communication connection to the vehicle (20). The invention further relates to a vehicle (20), an electric charging cable (30), a system (1), and a method for transmitting data within the framework of vehicle communication between an electric charging station (10) and a vehicle (20).