EV Charging Adaptor with Control Pilot Signal Generation
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Solution Overview
Problem
Electric vehicle users face inconvenience and safety concerns due to the bulkiness and weight of carrying a J1772 plug cord for AC Level One Charging, and the absence of a control pilot signal or proximity sensor signal prevents charging when using a conventional extension cord.
Innovation Solution
A compact adaptor plug with a J1772 vehicle connector and standard AC connector, including a control circuit for providing a control logic pilot signal and proximity sensor signal, allowing safe connection to a conventional grounded AC receptacle via a standard extension cord for emergency charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a J1772 plug cord is carried in the vehicle for AC Level One Charging, then charging capability is available, but the cord adds size, bulk, weight, and uncleanliness
Solution Approach 1:
The patent extracts the essential charging function from the bulky cord and concentrates it into a compact adaptor unit. The adaptor contains the J1772 vehicle connector and control circuitry, separating the charging capability from the extensive cord length that causes bulk and weight issues.
Solution Approach 2:
The adaptor serves multiple functions: it provides the J1772 vehicle connection, generates the control pilot signal, provides proximity sensor functionality, and limits current to safe levels. This multi-functionality consolidates what would otherwise require separate components into a single compact unit.
2Adaptability or versatility
If a J1772 plug cord is carried in the vehicle for AC Level One Charging, then charging capability is available, but the cord adds size and bulk
Solution Approach 1:
The patent extracts the essential charging function from the bulky cord and concentrates it into a compact adaptor unit. The adaptor contains the J1772 vehicle connector and control circuitry, separating the charging capability from the extensive cord length that causes bulk and weight issues.
3Ease of operation
If a conventional extension cord is used without control pilot signal, then charging can be attempted, but the absence of control pilot signal prevents charging
Solution Approach 1:
The adaptor acts as an intermediary between the conventional extension cord and the vehicle charging system. It translates the simple electrical connection from the extension cord into the proper J1772 protocol by generating the control pilot signal and proximity sensor signal, enabling reliable charging through conventional outlets.
Solution Approach 2:
The adaptor copies the essential control functions of a fixed charging station by generating synthetic control pilot and proximity sensor signals. This allows the vehicle's charging control logic to recognize and operate with the adaptor as if it were a proper J1772 charging station.
4Productivity
If high current charging is provided, then charging speed is improved, but safety risks increase when using conventional extension cords
Solution Approach 1:
The adaptor dynamically controls the current parameter to match the capabilities of conventional extension cords and outlets. By limiting current to safe levels while still providing effective charging, it resolves the contradiction between charging speed and safety for emergency charging scenarios.
Data Source
AI summary
An adaptor is provided for connecting an EV/PHEV charging system to a grounded extension cord that may be plugged into a conventional NEMA receptacle. A proximity detection switch is provided within the adaptor. A pulse width modulated signal is limited by the control logic to limit the current provided to the vehicle charging system so that the current drawn by the system does not exceed the current carrying capacity of the extension cord. The adaptor has a NEMA plug on one side and a J1772 connector receptacle on another side.