Detachable EVSE Power Cord Plug with PCB Temperature Sensing
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Solution Overview
Problem
Existing electric vehicle supply equipment (EVSE) power cords are typically permanently attached, requiring different EVSE for different AC power receptacles and necessitate dedicated temperature sensors with additional wires, increasing size and decreasing flexibility.
Innovation Solution
A power cord with a detachable design and a printed circuit board assembly (PCBA) within the plug, featuring an electronic controller and temperature sensor, which transmits data via a two-wire interface, and a protective housing to prevent damage and electrostatic discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dedicated temperature sensor with two dedicated wires is used for each connector blade, then temperature monitoring accuracy is improved, but the power cord size increases and flexibility decreases
Solution Approach 1:
The patent combines multiple temperature sensors and their signal transmission functions into a single integrated circuit board assembly. This consolidation allows temperature monitoring of multiple connector blades using shared wiring and processing resources, maintaining measurement precision while reducing the overall wire count and improving power cord flexibility.
Solution Approach 2:
The integrated circuit board assembly serves multiple functions: it monitors temperature for multiple connector blades, processes signals from all sensors, and communicates with the EVSE. This multi-functional design eliminates the need for separate dedicated wiring for each sensor, reducing complexity while maintaining monitoring accuracy.
2Reliability
If permanently attached power cords are used for different voltage and current requirements, then connection reliability is improved, but adaptability to different AC power receptacles decreases
Solution Approach 1:
The power cord is segmented into a permanent EVSE portion and a detachable plug portion. This allows the plug to be exchanged based on different AC power receptacle requirements (e.g., NEMA 5-15 for 120V, NEMA 14-50 for 220V) while maintaining a reliable permanent connection at the EVSE end. The detachable design enables adaptability without compromising connection reliability.
Solution Approach 2:
The power cord transitions from a static permanently-attached design to a dynamic detachable design. This allows the system to adapt its configuration based on different operational requirements and receptacle types, while the permanent EVSE portion maintains reliable connections. The dynamic nature enables flexibility in voltage and current configurations.
3Loss of information
If multiple dedicated wires are used for temperature sensor communication, then temperature data accuracy is improved, but device complexity increases
Solution Approach 1:
Multiple temperature sensor signals are merged and routed through a single integrated circuit board assembly. This consolidation reduces the number of separate wires needed while maintaining the ability to accurately capture and transmit temperature data from multiple connector blades. The integrated board handles signal processing and multiplexing efficiently.
Solution Approach 2:
The integrated circuit board assembly acts as an intermediary between the temperature sensors and the EVSE control system. It consolidates multiple sensor signals, performs necessary processing, and communicates with the EVSE through a streamlined interface, reducing wiring complexity while preserving temperature data accuracy.
Data Source
AI summary
The electric vehicle supply equipment described herein includes one or more power cords this is/are configured to be disconnected from and reconnected to the electrical vehicle supply equipment. The electric vehicle supply equipment so includes a printed circuit board assembly disposed within a plug of the power cord having an electronic controller configured to transmit data regarding a connector blade configuration of the plug and a printed circuit board assembly housing enclosing the printed circuit board assembly. The printed circuit board assembly housing is disposed within a plug housing of the plug.