EV Charger Split Architecture for Accessible Disconnect and Vandal Resistance
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Solution Overview
Problem
Existing electric vehicle (EV) charging systems are costly, prone to vandalism, and require a physical EV charger to be located away from the EV charging cord and connector set, making the breaker mechanism inaccessible and necessitating a separate, local disconnecting means.
Innovation Solution
An EV charger comprising a disconnect switch assembly with a preinstalled EV charging cord and connector, and an EV circuit breaker charger that can be installed remotely within a panelboard, connected to the disconnect switch assembly via a separate charging cord, providing a cost-effective and secure solution that meets NEC requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a wall charger with local disconnecting means is installed openly at every charging location, then the breaker mechanism is readily accessible, but the system becomes expensive and prone to vandalism
Solution Approach 1:
The system divides the EV charger into two separate components: a remote EV circuit breaker charger installed in a protected panelboard, and a local disconnect switch assembly installed at the charging location. This segmentation allows the valuable breaker mechanism to be protected while maintaining operational functionality through the local disconnect switch.
Solution Approach 2:
A local disconnect switch assembly acts as an intermediary between the remote EV circuit breaker charger and the EV charging cord/connector. This intermediary provides local accessibility for disconnecting power while the actual breaker mechanism remains protected in the remote panelboard, eliminating the need for expensive vandal-resistant enclosures at charging locations.
2Object-affected harmful factors
If the EV charger is located remotely within a panelboard, then the system is more secure and cost-effective, but the breaker mechanism becomes inaccessible where charging occurs
Solution Approach 1:
The system segments the breaker mechanism from the charging location, placing the EV circuit breaker charger in a protected remote panelboard while installing a local disconnect switch assembly at the charging location. This allows secure remote housing of valuable components while maintaining local operational accessibility.
Solution Approach 2:
The local disconnect switch assembly serves as an intermediary that provides accessible power disconnection at the charging location, while the actual EV circuit breaker charger remains securely installed in the remote panelboard. This intermediary solution satisfies both security requirements and operational accessibility needs.
3Reliability
If a separate local disconnecting means is installed, then NEC requirements are met, but the device complexity and installation cost increase
Solution Approach 1:
The local disconnect switch assembly is merged with the EV charging cord and connector into a single integrated unit. This combination satisfies NEC requirements for local disconnecting means while reducing the number of separate components and simplifying installation, as the disconnect switch is already incorporated into the charging assembly rather than being a separate installation requirement.
Data Source
AI summary
An electric vehicle (EV) charger includes a disconnect switch assembly including an EV connector structured to be inserted into a power receptacle for an EV, an EV charging cord coupled to the EV connector, and a disconnect switch box including a disconnect switch structured to connect or disconnect power supply to the EV and a terminal block structured to connect communications lines, where the disconnect switch box is structured to be installed at a charging space for the EV; and an EV circuit breaker charger couplable to the disconnect switch box via a separate EV charging cord and structured to be inserted within a panelboard remotely located from the charging space, the EV circuit breaker charger including a circuit interrupter structured to interrupt current from flowing to the EV in an event of fault, an EV charger structured to supply power to the EV, and a communications component structured to communicate with the EV via the communications lines.