Wake-by-CTRLPLT Circuit for EV Onboard Battery Charger Sleep Mode
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Solution Overview
Problem
Existing wake-up circuits for vehicles from sleep mode when connected to a charging station are inefficient, as they cannot handle scenarios where the CTRLPLT signal is set to high without additional hardware or draw excessive sleep current, making them sub-optimal for plug-in electric vehicles.
Innovation Solution
A Wake-by-CTRLPLT circuit that includes an input attenuator, PWM detector, peak detector, and edge detector, powered by an ultra-low sleep current lower voltage power source, generates wake-up signals to the OBC controller to exit sleep mode, handling various charging scenarios, including delayed charge modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing wake-up circuits are used to wake the vehicle from sleep mode, then the vehicle can be awakened when connected to a charging station, but the circuits draw excessive sleep current or cannot handle high CTRLPLT signal scenarios
Solution Approach 1:
The wake-up circuit is segmented into multiple functional blocks: input attenuator, PWM detector, peak detector, and edge detector. Each block performs a specific function with optimized power consumption characteristics, allowing the overall circuit to wake the vehicle reliably while maintaining ultra-low sleep current.
Solution Approach 2:
The circuit changes its operational parameters dynamically - during sleep mode it operates at ultra-low current consumption, and during wake-up it activates full functionality. The input attenuator adjusts signal levels, and the detectors operate at different sensitivity thresholds to optimize power consumption while maintaining reliable wake-up detection.
2Adaptability or versatility
If additional hardware is added to handle high CTRLPLT signal scenarios, then the circuit can handle various charging scenarios, but the device complexity increases
Solution Approach 1:
The wake-up circuit is designed as a universal solution that handles multiple charging scenarios including delayed charge modes, high CTRLPLT signals, and standard charging connections. The combination of PWM detection, peak detection, and edge detection enables the single circuit to adapt to various charging station configurations without requiring additional specialized hardware.
Solution Approach 2:
The input attenuator serves as an intermediary element that conditions the incoming CTRLPLT signal before it reaches the detection stages. This intermediary component allows the circuit to handle high voltage signals and various signal formats without requiring complex protection or conditioning circuits elsewhere in the design.
3Productivity
If the wake-up circuit handles delayed charge modes and high CTRLPLT signals, then charging operations are more efficient, but the circuit requires more complex detection mechanisms
Solution Approach 1:
The circuit performs preliminary detection and conditioning of the CTRLPLT signal through the input attenuator and PWM detector before committing to full wake-up operation. This preliminary action allows the circuit to efficiently identify valid wake-up conditions and reject invalid signals, improving charging efficiency while keeping the detection logic manageable through staged processing.
Data Source
AI summary
An on-board battery charging system for a plug-in electric vehicle has a charging unit for charging a high-voltage battery and a controller for controlling and managing current flow used to support charging related operations for the high-voltage battery. The controller may detect a connection between the on-board battery charging system and electric vehicle supply equipment (EVSE) and is configured to enter a sleep mode when a control pilot signal from the EVSE is either absent or indicative of a delayed charge mode. The charging system may include a wake-by-control pilot circuit operable to wake the controller from the sleep mode when the control pilot signal is detected and when the control pilot signal transitions from a non-zero static DC voltage to an active PWM signal.