EV Charging Phase Order Detection Using Asymmetric Current Draw
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Solution Overview
Problem
Existing techniques for determining and correcting phase order connections in electric vehicle supply equipment (EVSE) rely on manual inspection, leading to inefficient charging due to incorrect phase connections, which can cause uneven current distribution, overheating, and potential damage to charging units.
Innovation Solution
A computerized system on the vehicle uses a control routine to determine phase order by asynchronously drawing smaller currents on each phase, measuring consumption, and mapping the correct phase order through a regulator component and measurement component, optionally with machine learning and cloud integration to adjust current consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection is used to determine phase order, then simplicity of implementation is maintained, but productivity and reliability deteriorate due to inefficiency and potential for error
Solution Approach 1:
The EV itself performs the phase order determination by autonomously drawing different currents on different phases and measuring the results, eliminating the need for external manual inspection tools or personnel. The vehicle's onboard systems conduct the entire diagnostic process independently.
Solution Approach 2:
The manual mechanical inspection process is replaced with an automated electrical measurement system that uses current drawing and measurement components to electronically determine phase order, substituting human-operated mechanical methods with automated electrical diagnostics.
2Object-affected harmful factors
If incorrect phase connections are not detected, then device complexity remains low, but harmful factors increase due to uneven current distribution and overheating
Solution Approach 1:
The phase order determination is performed before the charging process begins, allowing any incorrect connections to be identified and corrected in advance. The system proactively checks phase connections prior to operation to prevent harmful effects during charging.
Solution Approach 2:
The measurement component provides feedback information about current consumption on each phase, allowing the system to identify incorrect phase connections based on asymmetric current distribution patterns and take corrective action.
3Reliability
If automated phase order determination is implemented, then productivity and reliability improve, but ease of operation deteriorates due to increased system complexity
Solution Approach 1:
The phase order determination function is merged with the existing charging control system, using the same communication interface and control routines. The regulator component that normally controls charging current is also used to draw diagnostic currents, combining multiple functions into existing system components.
Solution Approach 2:
The measurement and control components are designed to serve multiple purposes: they function both during normal charging operations and during phase order determination diagnostics, eliminating the need for separate dedicated diagnostic hardware and simplifying overall system operation.
Data Source
AI summary
Systems/techniques that facilitate determination of phase order of a connection point via a control routine are provided. In various embodiments, a system can generate a control routine to determine a phase order of an electric vehicle supply equipment (EVSE) to which the EV is connected and a phase order of a connection point via asynchronous operation of phases. In various aspects, the system can draw, by the EV and via the control routine, a smaller current in one phase than other phases for a measurable time. In various cases, the system can adjust, locally in the EV or via a connected cloud, an external device, or the EVSE, a maximum current to draw or deliver by the EV per phase based on the phase order determined.