EV Charger Protocol Conversion for OCPP and OPC Console Control
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Solution Overview
Problem
Industrial control systems, which monitor and control field devices such as variable speed drives and ION meters, lack compatibility with the Open Charge Point Protocol (OCPP), making it impossible to directly control electric vehicle charging stations using OPC DA/UA Servers, necessitating a solution for interoperability between different communication protocols.
Innovation Solution
A system that enables electric vehicle chargers to operate as clients in a client-server configuration with a dedicated OCPP server, using multiple communications protocols and a conversion module to facilitate communication between OCPP, HTTP, MODBUS TCP/IP, and OPC protocols, allowing central control consoles to control both electric vehicle chargers and industrial equipment without requiring OCPP compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If industrial control systems use OPC DA/UA Servers to control field devices, then they can effectively monitor and control industrial equipment, but they cannot directly control electric vehicle charging stations due to protocol incompatibility
Solution Approach 1:
The patent introduces an intermediary gateway device that acts as a protocol translator between the OPC-based industrial control system and the OCPP-based charging station. The gateway receives commands from the OPC server, translates them into OCPP protocol messages, and forwards them to the charging station, enabling indirect control without requiring the industrial control system to speak OCPP directly
Solution Approach 2:
The gateway device is designed to handle multiple communication protocols simultaneously, serving as a universal interface that can translate between OPC DA/UA, OCPP, and potentially other industrial protocols. This multi-functionality allows a single device to bridge different protocol ecosystems without requiring separate dedicated translators for each protocol pair
2Reliability
If electric vehicle chargers use the OCPP protocol for communication, then they can achieve standardized charging control, but they cannot be controlled by existing industrial control consoles that use OPC protocols
Solution Approach 1:
The gateway serves as a mediator that allows the OCPP protocol to maintain its standardized charging control functionality while simultaneously enabling access from OPC-based control consoles. The gateway translates OPC commands into OCPP messages, preserving the integrity of both protocols while enabling cross-protocol operation
3Adaptability or versatility
If a direct control connection is established between OPC servers and OCPP charging stations, then protocol compatibility would be achieved, but the system complexity and conversion requirements would increase
Solution Approach 1:
Rather than attempting direct integration between OPC servers and OCPP charging stations, the patent employs an intermediary gateway that handles all protocol conversion. This approach actually reduces overall system complexity by concentrating the conversion logic in a single dedicated device rather than requiring each end system to implement multiple protocol stacks
Data Source
AI summary
Systems and methods for controlling electric vehicle chargers using central control consoles for controlling and communicating with industrial equipment. The electric vehicle chargers operate as clients in a client-server configuration with a dedicated OCPP server. The OCPP server communicates with a control console using either of two communications paths—one path uses a direct HTTP connection with the control console. For this path, the control console operates as a web-enabled client. For the other path, multiple communications protocols are used and conversions between these protocols are effected using a conversion module and a MODBUS server. The MODBUS server communicates with the OCPP server. The MODBUS server also communicates with the control console by way of the conversion module and a control server. The control console is thereby able to control multiple pieces of industrial equipment along with the electric vehicle chargers without needing to be compliant with the OCPP protocol.