Hardware Interface Adapter for EV Charging Cable Data Line
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Solution Overview
Problem
Current charging infrastructure for battery-electric vehicles faces challenges in cost-effectively implementing communication between diagnostic PCs and in-cable control boxes due to the need for additional hardware interfaces or modules, which complicates firmware updates and error diagnosis while maintaining IP protection standards.
Innovation Solution
A hardware interface adapter is used to facilitate communication between the in-cable control box and a diagnostic PC, employing serial interfaces and modulation techniques like amplitude shift keying and pulse width modulation to utilize existing data lines without additional modules, ensuring compatibility with IEC standards and allowing simultaneous charging and data exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional communication modules (PLC, WLAN, Bluetooth) are integrated into the in-cable control box, then communication capability with diagnostic PC is improved, but cost and device complexity increase
Solution Approach 1:
The existing data line, originally designed solely for communication between the in-cable control box and the battery-electric vehicle, is made multi-functional by enabling it to also carry communication signals between the in-cable control box and the diagnostic PC. This universal usage eliminates the need for separate communication modules while maintaining all required communication capabilities.
Solution Approach 2:
The in-cable control box's internal communication infrastructure (data line and processor) is leveraged to serve the additional function of communicating with external diagnostic equipment. The system uses its own existing resources rather than requiring external or additional dedicated components, thereby reducing complexity and cost.
2Ease of operation
If a diagnostic connector is integrated into the charging cable housing, then communication access is improved, but IP protection rating and insulation requirements are compromised
Solution Approach 1:
The existing data line, originally designed solely for communication between the in-cable control box and the battery-electric vehicle, is made multi-functional by enabling it to also carry communication signals between the in-cable control box and the diagnostic PC. This universal usage eliminates the need for separate communication modules while maintaining all required communication capabilities.
Solution Approach 2:
The in-cable control box's internal communication infrastructure (data line and processor) is leveraged to serve the additional function of communicating with external diagnostic equipment. The system uses its own existing resources rather than requiring external or additional dedicated components, thereby reducing complexity and cost.
3Reliability
If powerline communication (PLC) is used to communicate with the in-cable control box, then communication capability is improved, but hardware cost increases due to required PLC modules
Solution Approach 1:
The existing data line, originally designed solely for communication between the in-cable control box and the battery-electric vehicle, is made multi-functional by enabling it to also carry communication signals between the in-cable control box and the diagnostic PC. This universal usage eliminates the need for separate communication modules while maintaining all required communication capabilities.
Solution Approach 2:
The in-cable control box's internal communication infrastructure (data line and processor) is leveraged to serve the additional function of communicating with external diagnostic equipment. The system uses its own existing resources rather than requiring external or additional dedicated components, thereby reducing complexity and cost.
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 reduces costs by eliminating the need for additional communication modules, enabling efficient data transfer and firmware updates while maintaining safety and compatibility standards, allowing for bidirectional communication and increased data transfer rates during charging processes.
Implementation Method 1
employing serial interfaces and modulation techniques like amplitude shift keying and pulse width modulation
Implementation Method 2
employing serial interfaces and modulation techniques like amplitude shift keying and pulse width modulation
Data Source
Figure 1
Figure 2
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AI summary
Method for communication between an external computer (8) and a charging cable with an in-cable control box (3) for charging battery electric vehicles (6), wherein the charging cable has a data line (11) for communication with the vehicle (6) and a hardware interface (7) between the in-cable control box (3) of the charging cable and the computer (8) enables access to the data line (11) by means of the computer (8), wherein data for the in-cable control box (3) of the charging cable is sent from the computer (8) to the hardware interface (7), modulated by the hardware interface (7) onto the signal (4) of the data line (11) and thus transmitted to the in-cable control box (3) of the charging cable, while data for the computer (8) is sent from the in-cable control box (3) of the charging cable via the signal (4) of the data line (11), converted by the hardware interface (7) and sent to the computer (8). to be sent and which is characterized by this.that the data from the in-cable control box (3) of the charging cable to the computer (8) is modulated from the in-cable control box (3) of the charging cable by a modification of the pulse width (13) of the signal (4) of the data line (11) and sent to the hardware interface (7), which forwards the data to the computer (8).