Dual-Switch EV Charging Cable for AC and DC Circuit Routing
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Solution Overview
Problem
The electric vehicle charging industry faces significant challenges due to the presence of multiple standards for communication, control, and physical connections between EV chargers and vehicles, leading to increased costs and complexity, with no single global standard in sight, necessitating a solution that allows for universal charging across different vehicle types and regions.
Innovation Solution
A charging apparatus with a dual-switch system that can seamlessly connect to both AC and DC charging circuits using a single vehicle on-board charging inlet and charging cable, allowing for adaptable power transfer and communication, enabling charging of various electric vehicles regardless of their standard configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple charging standards (CHAdeMO, GB/T, CCS) are supported through separate connectors and circuits, then compatibility with different vehicle types is improved, but device complexity and cost increase significantly
Solution Approach 1:
The patent implements a universal charging apparatus where a single charging cable with integrated AC and DC charging circuits can charge different vehicle types (BEV, PHEV, EV) through one on-board charging inlet. The system uses switches to route power between AC charging circuit (connected to vehicle on-board charger) and DC charging circuit (connected directly to battery), enabling one cable to replace multiple standard-specific connectors
Solution Approach 2:
The patent merges AC charging circuit and DC charging circuit into a single integrated charging cable that connects to one vehicle on-board charging inlet. The control system combines switching control for routing power between AC and DC circuits, eliminating the need for separate connectors for each charging standard
2Ease of operation
If AC charging circuit and DC charging circuit are integrated in one charging cable, then ease of operation is improved, but safety risks increase due to potential simultaneous connection
Solution Approach 1:
The patent employs a control system that monitors the charging state and switching positions to prevent harmful conditions. The control method detects when the charging cable is connected and automatically controls the switches to ensure only one charging circuit (AC or DC) is active at a time, providing feedback control to maintain safe operating conditions
Solution Approach 2:
The patent introduces switches as intermediary components between the power source and the vehicle battery. These switches act as mediators that control and isolate the AC charging circuit and DC charging circuit, ensuring they cannot operate simultaneously and preventing short circuits while allowing easy switching between charging modes
Data Source
AI summary
This specification describes a charging apparatus for use in an electric vehicle charging system which comprises an AC charging circuit connected to an AC power source, a DC charging circuit connected to a DC power source or the AC power source, the charging apparatus comprising: a first switch; a second switch; and a charging cable comprising a plurality of power lines, wherein each of the first switch and the second switch comprises a plurality of poles and a plurality of sets of contacts, wherein the plurality of poles corresponds to the plurality of power lines of the charging cable, the first switch is configured to move the plurality of poles of the first switch between a first position wherein the plurality of power lines of the charging cable is connected to a first set of contacts of the first switch connected to the AC charging circuit, and a second position wherein the plurality of power lines of the charging cable is not connected to the first set of contacts of the first switch connected to the AC charging circuit, and the second switch is configured to move the plurality of poles of the second switch between a first position wherein the plurality of power lines of the charging cable is connected to a first set of contacts of the second switch, and a second position wherein the plurality of power lines of the charging cable is not connected to the first set of contacts of the second switch.