EVSE Case with Configurable AC Plug and Compact Layout
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Solution Overview
Problem
Existing electric vehicle supply equipment (EVSE) systems face challenges in safety, efficiency, and reliability, particularly in managing power distribution and detecting faults, while also failing to effectively prevent excessive electrical-induced heat and adapt to different AC power receptacle configurations.
Innovation Solution
The EVSE system incorporates a compact design with a relay and controller setup that ensures safe power distribution by only energizing the contactors when connected to a vehicle, includes methods for fault detection using differential DC bias voltage, and features a configurable AC plug apparatus that can identify and adapt to various NEMA standardized AC power receptacles, while also monitoring temperatures to prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the EVSE uses standard AC utility power from a standard utility socket, then the device can be deployed in common locations, but the device must adapt to different NEMA standardized AC power receptacle configurations
Solution Approach 1:
The EVSE incorporates a configurable AC plug apparatus with rotatable plug blades that can dynamically adjust their orientation to match different NEMA standardized receptacle configurations. The plug blade assembly includes rotational joints allowing the plug to adapt its configuration based on the receptacle type encountered, enabling versatility without requiring multiple fixed plug designs.
2Reliability
If the EVSE minimizes energized components by only energizing contactors when connected to a vehicle, then safety is improved, but the device must implement complex fault detection mechanisms
Solution Approach 1:
The EVSE implements a preliminary connection verification process where the system detects the presence of a vehicle connection through pilot signal communication before energizing the contactors. This preliminary action ensures that power is only transferred when a proper connection is established, enhancing safety while using a relatively simple detection mechanism based on standard EVSE communication protocols.
Solution Approach 2:
The EVSE employs feedback mechanisms where the controller continuously monitors the pilot duty signal from the connected vehicle to verify proper connection and communication. This feedback loop allows the system to maintain safety by only energizing components when the feedback confirms a valid connection, implementing a straightforward safety mechanism through continuous monitoring rather than complex fault detection.
3Length of stationary object
If the EVSE uses a compact design with distance from front plug face to rear face less than or equal to 3.1 inches, then the device fits in standard enclosures, but the internal component layout becomes constrained
Solution Approach 1:
The EVSE adopts a trapezoidal prism cross-section design where the case width varies along its length, creating additional spatial dimensions for component arrangement. This geometric approach allows the internal components to be distributed in three-dimensional space more efficiently, fitting complex electronics and power components within a compact 3.1-inch length by utilizing width and height variations rather than requiring linear spacing.
Solution Approach 2:
The EVSE implements a nested arrangement where the controller, relay, and other electronic components are housed within a compact EVSE case that itself fits within standard outdoor plug enclosures. The internal components are arranged in a nested configuration where smaller components are positioned within the volume created by larger components, maximizing space utilization within the constrained 3.1-inch length.
Data Source
AI summary
An electric vehicle service equipment (EVSE) system includes an EVSE case having a front plug face, a rear face, and left and right gripping sides that collectively define a trapezoidal prism cross section, the left and right gripping sides further having left and right convex gripping portions, respectively, a relay positioned within the EVSE case, and a controller positioned within the EVSE case and in communication with the relay, the controller responsive to a pilot duty signal, when a pilot duty signal is present.