EV Charger Current Control Using Sub-G Panel Load Feedback
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Solution Overview
Problem
The rapid adoption of electric vehicles poses a challenge as existing residential electrical infrastructure often lacks sufficient capacity to support simultaneous charging of multiple EVs, leading to frequent tripping of main breakers and inconvenience for homeowners, with current solutions like PLC, 2.4G, and cellular communication being expensive and unreliable.
Innovation Solution
A sub-G communication system using non-contact current transformers and short-range wireless communication modules allows the EV charger to adjust its current draw in real-time, ensuring it does not exceed the home's electrical capacity, thereby preventing breaker tripping and enabling simultaneous use of other high-load appliances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If Level II charger provides 220V at 30-40 Amps for EV charging, then charging capability is improved, but home electric power capacity is exceeded causing breaker tripping
Solution Approach 1:
The EV charger dynamically adjusts its current draw based on real-time monitoring of home panel capacity. The system transitions from a fixed 30-40 Amp output to a variable output that adapts to available capacity, preventing breaker tripping while maximizing charging speed when capacity permits.
Solution Approach 2:
The system implements feedback by monitoring the home panel's current capacity through communication with the breaker panel and adjusting the charging current accordingly. This closed-loop control ensures the charger operates within safe limits while optimizing charging performance.
2Reliability
If expensive PLC, 2.4G, or cellular communication is used for current monitoring, then communication capability is improved, but system cost increases
Solution Approach 1:
The system replaces expensive communication technologies (PLC, 2.4G, cellular) with a low-cost alternative that uses existing power line infrastructure for communication. This approach achieves reliable communication at a fraction of the cost, making the solution economically viable for widespread adoption.
Solution Approach 2:
The system uses the existing electrical power infrastructure as an intermediary for communication between the charger and breaker panel. By leveraging the power lines already present in the home, the system avoids the need for separate communication infrastructure, reducing costs while maintaining reliability.
3Power
If dedicated circuitry and wiring is installed for Level II charging, then charging infrastructure capability is improved, but installation cost and complexity increases
Solution Approach 1:
The system enables existing electrical infrastructure to serve multiple functions - both general home power distribution and EV charging. By allowing the charger to dynamically adapt to available capacity on the existing panel, the system eliminates the need for dedicated charging circuits, reducing installation complexity and cost.
Solution Approach 2:
The EV charger performs self-assessment of home panel capacity and self-adjusts its operating parameters without requiring pre-configuration or dedicated infrastructure. This autonomous adaptation simplifies installation by eliminating the need for complex pre-wiring and professional installation of dedicated charging circuits.
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
This solution provides reliable, cost-effective, and efficient management of electrical loads, allowing multiple appliances to operate concurrently without disrupting power, thus enhancing user convenience and reducing the need for costly infrastructure upgrades.
Implementation Method 1
a sub-G communication module for receiving current reading from an ammeter
Implementation Method 2
an ammeter connected to a main breaker panel that is separate from the electric vehicle charging device
Data Source
AI summary
The present disclosure provides methods and structures for controlling current of an electric vehicle charger. In one embodiment, the electric vehicle charger includes a sub-G communication module in electrical communication in a micro control unit of the electrical vehicle charging device, the sub-G communication module for receiving a current reading from an ammeter connected to a main breaker panel that is providing current to at least the electrical vehicle charging device; and a microcontroller including instructions for reducing the current draw of the electrical charger when the current reading from the ammeter reaches a threshold value for avoiding throwing the main disconnect breaker of the main breaker.