EV Controller Sleep Mode Management for Errant Signal Detection

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Solution Overview

Problem

Electric vehicle charging systems can malfunction due to erratic control pilot signals from electric vehicle supply equipment, leading to depletion of the vehicle's 12V battery when frequent changes in the signal prevent usable energy conversion, causing the vehicle to appear not charged without the owner's knowledge.

Innovation Solution

Implementing a multi-timer system to differentiate between charging and non-charging times, resetting timers when the plug is removed or charging is successful, and disabling further monitoring of erratic control pilot signals after a predefined period of non-charging to prevent further battery drain.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the controller monitors control pilot signal changes frequently to detect charging status, then charging detection accuracy is improved, but power consumption increases causing 12V battery depletion

Engineering Contradiction:

Improvecharging detection accuracyVSAvoidpower consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The controller implements periodic monitoring of control pilot signal changes with a predefined threshold frequency. When the rate of signal changes exceeds this threshold over a monitoring period, the controller identifies erratic behavior and stops monitoring to conserve battery power. This periodic evaluation approach maintains charging detection accuracy during normal operation while preventing excessive power consumption during abnormal conditions.

Inventive Principle:

Principle #19Periodic action

2Reliability

If the controller remains in wake mode to monitor control pilot signals continuously, then charging status monitoring is improved, but battery power is drained unnecessarily

Engineering Contradiction:

Improvecharging status monitoringVSAvoidbattery power drain

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The controller performs preliminary evaluation of control pilot signal changes by counting the number of changes within a predefined time period. Only when this count exceeds a predetermined threshold does the controller transition from sleep mode to wake mode for detailed charging status monitoring. This preliminary filtering action ensures reliable monitoring is activated only when necessary, preventing unnecessary battery power drain during normal charging operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The controller continuously monitors the frequency of control pilot signal changes and uses this feedback to dynamically adjust its operational state. When signal changes remain within acceptable thresholds, the controller maintains sleep mode to conserve energy. When changes exceed thresholds, feedback triggers wake mode for active monitoring. This feedback mechanism ensures reliable charging status monitoring while minimizing unnecessary battery power consumption.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20230058031A1Errant electric vehicle supply equipment detection and management

Publication Date: 2023.02.23 FORD GLOBAL TECH LLC

AI summary

A vehicle includes control pilot circuitry, connected with a charge port, that carries a control pilot signal from electric vehicle supply equipment, and a controller that exits a sleep mode and increases power consumption responsive to changes in the control pilot signal while a plug of the electric vehicle supply equipment is mated with the charge port and an accumulated time associated with the changes remains less than a predefined value.