EV Charging Cable Diagnostics With Safe Circuit Access
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Solution Overview
Problem
Conventional methods for diagnosing issues in electric vehicle charging are inefficient, unsafe, and often require direct access to internal hardware, posing risks to technicians and complicating the detection of charging errors.
Innovation Solution
A diagnostic apparatus that includes an input connector unit, output connector unit, circuit network, and testing ports, allowing safe and direct access to charging cable wiring for real-time measurement of electrical signals, including inductive current measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If a repair technician directly accesses internal hardware of the charging station or EV to diagnose charging issues, then diagnostic capability is improved, but safety risk and operational complexity increase significantly
Solution Approach 1:
The patent introduces a diagnostic device as an intermediary component that connects between the charging station and the EV through the charging cable. This device provides circuit accesses that allow technicians to measure electrical signals without directly accessing internal hardware of either the charging station or EV, thereby maintaining diagnostic capability while eliminating safety risks associated with direct hardware access
2Loss of information
If proprietary reporting from hardware is used for diagnosis, then information availability is improved, but diagnostic completeness deteriorates due to limited accessibility and functionality
Solution Approach 1:
The diagnostic device enables self-service diagnostics by allowing technicians to directly measure electrical signals (voltage, current, resistance) at multiple points in the charging circuit. This eliminates reliance on proprietary reporting systems while providing comprehensive diagnostic information through direct measurement capabilities
3Productivity
If charging cable wiring is made accessible for measurement, then diagnostic efficiency is improved, but device complexity and safety hazards increase
Solution Approach 1:
The diagnostic device is nested within the existing charging cable infrastructure. The circuit accesses are integrated into the charging cable assembly, allowing technicians to access measurement points without adding external complexity to the charging system. The device leverages the existing cable structure rather than requiring separate diagnostic equipment
Data Source
AI summary
A diagnostic apparatus for electric vehicle charging is provided. In some aspects, the diagnostic apparatus includes an input connector unit comprising a plurality of inputs that receive electrical signals from a charging station for electric vehicle charging, and an output connector unit comprising a plurality of outputs that send electrical signals to an electric vehicle. The diagnostic apparatus also includes a circuit network electrically connecting corresponding inputs of the plurality of inputs to outputs of the plurality of outputs, and a housing at least partially enclosing the circuit network. The diagnostic apparatus further includes at least one circuit access that exposes at least a portion of the circuit network.