EV Cordset Fault Interface Using Duty-Cycle Light Encoding

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Solution Overview

Problem

Current electric vehicle cordsets have limited light combinations for fault indication, making it difficult to specifically identify and locate faults, and user interpretation can lead to misidentification.

Innovation Solution

A cordset controller with fault detection circuits and status lights that encode faults through modulating the duty cycle of an amber status light, allowing a visual processing module to decode and display the fault type and location.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple lights are used to indicate different faults, then the number of identifiable faults increases, but the device complexity and cost increase

Engineering Contradiction:

Improvenumber of identifiable faultsVSAvoidnumber of lights

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single amber status light performs multiple functions by encoding different fault types through duty cycle modulation. The same physical light component conveys multiple fault information states, eliminating the need for multiple separate indicator lights while maintaining comprehensive fault identification capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent changes the operational parameters of the status light by modulating its duty cycle to encode different fault types. By varying the duty cycle parameter (percentage of time the light is on), the system can indicate multiple different faults using a single light, thus reducing hardware complexity while increasing information capacity

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If more lights are added to the cordset, then more fault types can be identified, but the ease of operation and user interpretation becomes more difficult

Engineering Contradiction:

Improvefault identification capabilityVSAvoiduser interpretation

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system incorporates a visual processing module that actively monitors the modulated light signal, decodes the duty cycle information, and translates it into human-readable fault descriptions displayed on a screen. This feedback mechanism bridges the gap between the encoded light signal and user understanding, making the system both versatile and easy to operate

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The visual processing module and display serve as an intermediary between the encoded light signal and the user. Instead of requiring users to directly interpret complex light combinations, the intermediary system automatically decodes and presents clear fault information, simplifying user interaction while maintaining comprehensive fault identification

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If a single light is used to indicate faults, then the device complexity is reduced, but the measurement precision and fault location capability deteriorates

Engineering Contradiction:

Improvenumber of status lightsVSAvoidfault location precision

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The system uses periodic modulation of the light signal with different duty cycles to encode specific fault information. By varying the temporal pattern (periodic on/off cycles) of the single light, the system can precisely indicate different fault types and locations, maintaining measurement precision while reducing device complexity

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent adds a temporal dimension to the light indication by using duty cycle modulation. Instead of relying solely on the spatial arrangement of multiple lights, the system encodes information in the time domain through varying the light's on/off patterns, thereby achieving precise fault identification with a single light component

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Enables precise identification and display of cordset faults, reducing misinterpretation and facilitating fault location, thereby improving user understanding and reducing warranty claims.

Implementation Method 1

encode the fault in the first status light through modulating the first status light. In one aspect, the fault is encoded by altering a duty cycle of the first status light.

Methodology Applied

Scientific EffectDuty cycle modulation:

Data Source

PatentUS12479321B2Electric vehicle cordset fault status human-machine interface

Publication Date: 2025.11.25 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

The present disclosure is directed to an electric vehicle cordset and system for identifying faults in an electric vehicle cordset. The electric vehicle cordset and system include a cordset controller. The cordset controller includes a cordset processor, a plurality of fault detection circuits connected to the cordset processor, and a first status light connected to the cordset processor. The cordset processor is configured to execute a set of instructions including identify a fault in one of the fault detection circuits, terminate power in the cordset, turn on the first status light indicating the fault is present, and encode the fault in the first status light through modulating the first status light.