EVSE Power Cord Plug PCB for Receptacle ID and Temperature Sensing
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Solution Overview
Problem
Existing electric vehicle supply equipment (EVSE) power cords are typically permanently attached and require multiple configurations for different AC power receptacles, necessitating separate EVSE for various voltage and current requirements, and often use dedicated temperature sensors that increase cord size and reduce flexibility due to the need for additional wires for temperature monitoring.
Innovation Solution
A power cord with a printed circuit board assembly in the plug that includes an electronic controller and temperature sensor, allowing for digital transmission of connector blade configuration and temperature data over a two-wire interface, enabling a common interface for various EVSE configurations and reducing wire count by integrating temperature monitoring within the cord.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dedicated temperature sensors with two dedicated wires are used for each connector blade, then temperature monitoring accuracy is improved, but the power cord size increases and flexibility decreases
Solution Approach 1:
The patent combines multiple temperature sensing functions into a single integrated temperature sensor that monitors both connector blades simultaneously. This consolidation eliminates the need for separate dedicated sensors and wires for each blade, reducing the overall wire count and power cord complexity while maintaining accurate temperature monitoring capability.
Solution Approach 2:
The temperature sensor is designed to serve multiple functions: monitoring both connector blades for overtemperature conditions and providing data through a shared communication interface. This multi-functional approach allows one sensor to replace what would traditionally require two separate sensors, thereby reducing device complexity.
2Reliability
If power cords are permanently attached to EVSE, then connection reliability is improved, but adaptability to different AC power receptacles decreases
Solution Approach 1:
The patent implements a retractable power cord mechanism that allows the power cord to be dynamically extended or retracted based on operational needs. This dynamic design enables the EVSE to maintain a compact form when the cord is retracted while providing full functionality when extended, effectively combining the reliability of permanent attachment with the adaptability of removable cords.
Solution Approach 2:
The power cord is designed to nest within the EVSE housing when not in use, similar to a nested doll structure. This allows the cord to be permanently integrated into the EVSE unit while maintaining the ability to be deployed when needed, achieving both connection reliability and adaptability to different receptacle configurations.
3Adaptability or versatility
If multiple EVSE units are used for different voltage and current requirements, then compatibility with various AC power receptacles is improved, but system complexity and cost increase
Solution Approach 1:
The EVSE is designed with a universal power cord interface that can accommodate different AC power receptacle configurations through the retractable cord mechanism. The electronic controller adapts to different voltage and current requirements programmatically, allowing a single EVSE unit to perform the functions that would traditionally require multiple specialized units, thereby reducing system complexity and cost.
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5B
AI summary
The electric vehicle supply equipment described herein includes one or more power cords (100) this is/are configured to be disconnected from and reconnected to the electrical vehicle supply equipment. The electric vehicle supply equipment also includes a printed circuit board assembly (102) disposed within an electrical plug (104) of the power cord (100) having an electronic controller configured to transmit data regarding a connector blade configuration of the plug (104) and a printed circuit board assembly housing (104) enclosing the printed circuit board assembly (102). The printed circuit board assembly housing (104) is disposed within a plug housing (128) of the electrical plug (104).