EV Charging Contactor Control via Predictive Habit Learning
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Solution Overview
Problem
Existing vehicle charging systems require contactors to open at vehicle shutdown, leading to increased wear, noise, and vibration when they need to close again for charging, disrupting the charging experience.
Innovation Solution
A vehicle charging system with a control module that predicts charging events based on learned user habits and maintains contactors in a closed position post-shutdown for a threshold time, connecting the traction battery pack to the charge port and preparing the vehicle for charging by opening the charge port door and illuminating the lighting module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactors are opened at vehicle shutdown, then vehicle safety is improved, but contactor wear increases and noise and vibration occur when they close again for charging
Solution Approach 1:
The control module predicts charging events based on learned user habits before the user actually charges the vehicle. When a charging event is predicted, the contactor is maintained in the closed position during vehicle shutdown, preparing the vehicle for charging in advance. This preliminary action prevents the harmful effects of contactor opening and closing while ensuring the vehicle is ready for charging.
Solution Approach 2:
The system uses learned charging habits and user behavior patterns as feedback to determine when to maintain the contactor closed. The control module continuously monitors and learns from charging events, adjusting its predictions to optimize contactor operation. This feedback mechanism allows the system to balance safety requirements with wear reduction by making intelligent decisions about contactor state based on predicted user actions.
2Ease of operation
If charging preparation actions are taken early, then charging experience is improved, but energy consumption increases
Solution Approach 1:
Preparation actions such as opening the charge port door and illuminating the charge port lighting module are performed only when a charging event is predicted. This preliminary action occurs in advance of the actual charging event, improving user experience by having everything ready when the user arrives. However, these actions are not taken continuously, only when needed based on predictions.
Solution Approach 2:
The system performs only the necessary preparation actions partially or selectively based on prediction confidence and specific conditions. Not all preparation actions are executed in every predicted charging scenario, allowing the system to balance user experience improvement with energy conservation by applying preparation actions only when most beneficial.
Data Source
AI summary
Systems and methods may predict vehicle charging events and prepare electrified vehicles for charging. Learned charging habits such as typical charging locations, charging times, and battery level when charging occurs may be leveraged for predicting when a user is likely to charge their electrified vehicle. A contactor system of the electrified vehicle may be controlled to maintain a set of contactors of the contactor system in a closed position upon vehicle shutdown in response to predicting that the charging event is likely. Maintaining the set of contactors closed when charging events are expected reduces contactor wear and decreases noise, vibration, and harshness, thereby facilitating a more satisfying user charging experience.