EV Charger Cable Length Extension via Ethernet Switch
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Solution Overview
Problem
Current electric vehicle supply equipment (EVSE) is limited by power-line communication standards, which restrict charging cable length to 10 meters to avoid electromagnetic interference and crosstalk, making it inadequate for longer charging applications like trucks, buses, ships, and planes.
Innovation Solution
Incorporating an Ethernet switch/router and a power-line communication device within the charging connector, using twisted-pair cables for communication between the charging connector and charger, allowing communication via Ethernet over twisted-pair instead of power-line communication, thus extending cable length beyond 10 meters without compromising signal quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If power-line communication standards are used for communication between charger and electrical vehicle, then communication can be established, but charging cable length is limited to 10 meters to avoid electromagnetic interference and crosstalk
Solution Approach 1:
The communication function is segmented into two parts: PLC communication device at the charging connector for short-distance communication with the vehicle, and Ethernet switch/router at the charger for long-distance communication. This segmentation allows the charging cable to be extended beyond 10 meters while maintaining reliable communication by using twisted-pair cables for the extended portion.
Solution Approach 2:
An Ethernet switch/router is introduced as an intermediary device between the PLC communication device and the charging network. This intermediary enables the system to overcome the 10-meter PLC communication limit by routing communication through Ethernet infrastructure, thereby supporting extended charging cable lengths without suffering from electromagnetic interference.
2Adaptability or versatility
If charging cable length is extended beyond 10 meters, then charging applications for trucks, buses, ships, and planes become feasible, but electromagnetic interference and communication reliability deteriorate
Solution Approach 1:
The charging connector is designed with multi-functionality, incorporating both PLC communication device for vehicle communication and Ethernet switch/router for network communication. This universal design enables the same charging infrastructure to serve diverse applications including cars, trucks, buses, ships, and planes with varying cable length requirements while maintaining communication reliability.
3Length of moving object
If PLC communication device is placed at the charger, then communication can be maintained, but cable length extension beyond 10 meters is not possible due to EMI limitations
Solution Approach 1:
The PLC communication device is extracted from the charger and relocated to the charging connector. This extraction separates the short-distance PLC communication function (limited to 10 meters) from the long-distance Ethernet communication function, allowing the charging cable to be extended beyond 10 meters while the PLC device remains within the safe communication zone near the vehicle.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable communication and extended charging cable lengths up to 100 meters, reducing electromagnetic interference issues and simplifying manufacturing by maintaining consistent PLC distance, independent of cable length, and improving electromagnetic compatibility.
Implementation Method 1
the charging cable comprises at least one twisted-pair cable extending between the charging connector and the charger
Implementation Method 2
the charging connector comprises a power-line communication PLC, device configured for communicating via power-line communication with the electrical vehicle
Data Source
Figure 1
Figure 2
AI summary
The invention relates to an Electric vehicle supply equipment comprising a charger (2) configured for supplying a charging current for charging an electrical vehicle (1), a charging connector (4) configured for connecting to the electrical vehicle (1) and a charging cable (3) connected with one end to the charger (2) and with another end to the charger (2) and configured for transmitting the charging current between the charging connector (4) and the charger (2), wherein the charging cable (3) comprises at least one twisted-pair cable (9) extending between the charging connector (4) and the charger (2), and the charging connector (4) comprises a power-line communication device (5) configured for communicating with the electrical vehicle (1) via the charging connector (4) and with the charger (2) via Ethernet over the at least one twisted-pair cable (9).