EVSE Fault Indicator System with Segmented Light Assemblies
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Solution Overview
Problem
Current electric vehicle charging systems fail to accurately identify the source of charging faults, often misleading customers and technicians by attributing faults to the EVSE assembly when they are actually related to the grid or vehicle.
Innovation Solution
The implementation of a fault indicator system within the EVSE assembly, comprising a control box, coupler, and plug with dedicated fault indicator light assemblies, which are illuminated by a control module to indicate whether the fault is within the EVSE, the vehicle, or the external power source, allowing for quick identification of the fault's origin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fault indicator is used on the EVSE assembly, then the device complexity is reduced, but the measurement precision of fault source identification deteriorates
Solution Approach 1:
The fault indicator system is segmented into three separate indicator assemblies distributed across different components: one on the control box (EVSE side), one on the coupler (vehicle interface side), and one on the plug (power source interface side). Each indicator independently identifies faults from its specific location, enabling precise fault source identification without requiring a complex centralized system.
2Measurement precision
If multiple fault indicator light assemblies are distributed across different components, then the fault source identification accuracy is improved, but the device complexity increases
Solution Approach 1:
Each fault indicator light assembly is locally integrated into its respective component (control box, coupler, or plug) with its own light source and housing. This local quality approach allows each indicator to independently provide accurate fault identification from its specific location without requiring complex inter-component coordination or centralized control.
3Ease of operation
If fault indicators are embedded within component housings, then the ease of operation is improved by providing clear visual feedback, but the manufacturing precision requirements increase
Solution Approach 1:
The light sources and their housings are pre-assembled as complete indicator assemblies before being integrated into the main components. This preliminary action allows for quality control and testing to be performed on each indicator assembly independently, reducing the manufacturing precision requirements during final integration while ensuring reliable visual feedback for users.
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 users to rapidly diagnose the source of charging faults, distinguishing between EVSE, vehicle, and external power source issues, thereby facilitating appropriate repairs and reducing unnecessary service visits.
Implementation Method 1
each of the first, second, and third fault indicator light assemblies includes an insert, a light source, and a printed circuit board (PCB)
Data Source
AI summary
An electric vehicle supply equipment (EVSE) assembly includes a control box including a first fault indicator light assembly, a coupler including a second fault indicator light assembly, and a plug including a third fault indicator light assembly. The fault indicator light assemblies can be illuminated to indicate charging faults.