EV Charging Voltage Limiting to Reduce Connector Arcing
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Solution Overview
Problem
Existing fast charging systems for electric vehicles face a risk of electrical arcs due to improper connection or wear of connectors, leading to potential damage and reduced service life of charging equipment.
Innovation Solution
Implementing an upper voltage limit, V_Lim_EVPresent, determined as a function of the EV's present voltage, to control the charging voltage and reduce the risk of arcs by limiting the potential difference between the EVSE connector and the vehicle inlet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high voltage and current are applied to enable rapid charging, then charging speed is improved, but the risk of electrical arcs and connector damage increases
Solution Approach 1:
The system performs preliminary verification of connector mechanical locking status and proper connection before enabling high voltage and current charging. This preliminary action prevents arcs by ensuring connections are secure before high power is applied.
Solution Approach 2:
The system continuously monitors connector status, mechanical locking state, and electrical parameters during charging. This feedback mechanism detects potential arc conditions and adjusts or terminates charging to prevent connector damage while maintaining high charging speeds when conditions are safe.
2Object-affected harmful factors
If connector locking mechanisms are made more reliable to prevent arcs, then arc risk is reduced, but device complexity increases
Solution Approach 1:
The system replaces reliance on purely mechanical locking mechanisms with electronic verification and control. Sensors and control systems monitor connection status and enable/disable charging based on verified proper connection, reducing arc risk without requiring more complex mechanical locking structures.
3Reliability
If continuous monitoring of connector status is implemented to detect arcs early, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The system uses the existing charging current path and electrical parameters to self-diagnose connection status and detect potential arc conditions. The charging system itself provides the monitoring function through measurement of electrical characteristics, eliminating the need for separate dedicated monitoring hardware.
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
Significantly reduces the occurrence and extent of electrical arcs, thereby protecting charging equipment and extending its service life.
Implementation Method 1
determining by the EVSE an EV Present Voltage provided by the EV battery at the inlet
Implementation Method 2
electrically charging the EV battery by the EVSE, wherein the charging includes applying a charging voltage V to the connector
Implementation Method 3
limiting the charging voltage V by an upper voltage limit V_Lim_EVPresent, wherein the upper voltage limit V_Lim_EVPresent is determined as a function of the EV Present Voltage
Data Source
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AI summary
The application concerns a method for charging or discharging an EV battery of an Electrical Vehicle, EV, using an Electrical Vehicle Supply Equipment, EVSE. The method comprises: Electrically coupling an EVSE charging interface conductor of the EVSE to an EV charging interface conductor of the EV and Determining, by the EVSE, an EV Present Voltage provided by the EV battery at the inlet; and at least one of electrically charging or discharging the EV battery by the EVSE. The charging includes applying a charging voltage V to the connector and limiting the charging voltage V by an upper voltage limit VLim_EVPresent and wherein the discharging includes applying a charging voltage V to the connector and limiting the charging voltage V by a lower voltage limit VLim_EVPresent. The upper voltage limit VLim_EVPresent is determined as a function of the EV Present Voltage.