EV Charging Arm Pulse Power With Fault-Safe Data Link
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Solution Overview
Problem
Electric vehicle charging systems are often slow and lack the necessary security to prevent damage to both the charging station and the electric vehicle, and they do not support efficient data collection for offload processing beyond what is available with Wi-Fi or cellular means.
Innovation Solution
The implementation of Fault Managed Power (FMP), which involves the transmission of high-power, high-voltage direct current pulse power with integrated fault detection and synchronization, allowing for safe and efficient charging while also enabling data communications through the same wire pair, ensuring continuous and uninterrupted power with safety features like touch-safe fault protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional charging systems are used, then charging can be performed, but charging speed is slow and efficiency is low
Solution Approach 1:
The system uses periodic pulse power delivery with alternating high-voltage charging pulses and low-voltage testing intervals. The controller alternates between delivering high-voltage DC pulses for rapid charging and switching to low-voltage mode for fault detection, creating a periodic cycle that enables both fast charging and safety monitoring without continuous high-voltage exposure
Solution Approach 2:
The charging system maintains continuous power delivery through overlapping pulse sequences where high-voltage charging pulses are delivered back-to-back with minimal interruption. The fault testing occurs during brief transition intervals between pulses, ensuring that the useful charging action continues nearly continuously while periodically inserting safety checks
2Productivity
If high-voltage power is transmitted for fast charging, then charging efficiency improves, but safety risks and damage potential increase
Solution Approach 1:
The system performs preliminary fault detection by switching to low-voltage mode before each high-voltage charging pulse is delivered. The controller actively tests for faults in the charging circuitry, contact plates, and wiring during these preliminary low-voltage intervals, identifying potential safety issues before high-voltage power is applied
Solution Approach 2:
When a fault is detected during the low-voltage testing phase, the system immediately skips the upcoming high-voltage charging pulse and terminates the charging session. This rushing through the safety check and immediately bypassing any dangerous state prevents the harmful effects from manifesting
3Loss of information
If separate communication systems are used, then data collection is possible, but system complexity and cost increase
Solution Approach 1:
The same physical wire pair used for power transmission is also used for data communication. The controller modulates communication signals onto the power delivery circuitry, allowing the charging connection to serve dual purposes: delivering high-voltage DC power and simultaneously transmitting charging status, fault information, and vehicle data without requiring separate communication wires
Data Source
AI summary
In one embodiment, an apparatus includes a power source and a moveable charging arm coupled to the power source and comprising a charging plate for contact with an electric vehicle contact plate. The charging arm is operable to transmit direct current (DC) pulse power with testing performed between high voltage pulses directly from the charging plate to the electric vehicle contact plate to charge one or more batteries at the electric vehicle. A method for charging the electric vehicle is also disclosed herein.