EV Charging Interlock for Shared Circuit Overload Prevention
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Solution Overview
Problem
Installing an electric vehicle charger often requires complex and invasive electrical work, such as adding a new circuit to a breaker panel, leading to high installation costs.
Innovation Solution
A system and method that uses an interlock device to interlock an electric vehicle supply with an existing circuit, managing load management by intercepting and admitting activation signals to prevent simultaneous power demand, thereby allowing less invasive installation and reducing circuit overloads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electric vehicle charger is installed by adding a new circuit to a breaker panel, then the charging system can operate independently and reliably, but the installation becomes complex and invasive with high costs
Solution Approach 1:
The patent merges the EV charger operation with an existing load circuit by using an interlock mechanism that allows the charger to share the circuit with another load (such as an air conditioner). The interlock device coordinates between the charger controller and the existing load controller to enable safe shared circuit usage, thereby avoiding the need to install a completely new dedicated circuit while maintaining system reliability.
2Ease of manufacture
If an electric vehicle charger shares an existing circuit with other loads, then installation costs and complexity are reduced, but the risk of circuit overload increases
Solution Approach 1:
The patent implements a feedback mechanism where the interlock device continuously monitors the operational state of both the EV charger and the existing load. When the charger detects that the existing load is active, it receives a signal to remain inactive, and vice versa. This real-time feedback coordination prevents simultaneous operation that could cause circuit overload, thereby enabling safe shared circuit usage while maintaining installation simplicity.
3Object-affected harmful factors
If an interlock device is used to coordinate between EV charger and existing load, then circuit overload is prevented, but the system complexity increases
Solution Approach 1:
The patent introduces an interlock device as an intermediary component that mediates between the EV charger controller and the existing load controller. This intermediary receives signals from both sides and coordinates their operation to prevent conflicts and overloads. By centralizing the coordination function in a single intermediary device, the system achieves reliable overload protection while keeping the overall architecture manageable and relatively simple.
Data Source
AI summary
A system and method for electric vehicle charging and load management is described. The system includes an interlock device for connection to an electric vehicle supply and an existing load. The interlock device is configured to: interrupt a control line of an existing load; interrupt a state line of the electric vehicle supply; and monitor the control and state lines for signals. In response to receiving concurrent activation signals for both the electric vehicle supply and the existing load, the interlock device transmits a signal to cease power delivery to the existing load. The interlock device then transmits a signal to activate the electric vehicle supply. The interlock device system and method therefore enables use of a single circuit by multiple loads while preventing simultaneous power delivery and thus circuit overload.