Patent Application
20190375299
The present disclosure relates to a charging assembly and a thermal management system for charging an electric vehicle.
Battery Electric Vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs) may require the use of an electric vehicle supplied equipment (EVSE) charger cord set which allows a vehicle operator to charge the vehicle in a garage or at other locations having a 110 VAC outlet, a 220 VAC outlet, or both a 110 VAC outlet and a 220 VAC outlet.
In at least one approach, a vehicle charger assembly is provided. The vehicle charger assembly may include a plug including a first temperature sensor, and an adapter mechanically and electrically couplable to the plug and including a second temperature sensor. The vehicle charger assembly may further include a charge circuit interrupting device (CCID) in electrical communication with the plug and the adapter and adapted to reduce a charging current in response to a charging temperature associated with one or both of the first and second temperature sensors exceeding a threshold charging temperature.
In at least one approach, a method for controlling vehicle charging is provided. The method may include, at a charge circuit interrupting device (CCID) that is electrically connected to a plug and an adapter electrically connected to the plug, monitoring a first charging temperature in the plug and a second charging temperature in the adapter. The method may further include, at the CCID, reducing a charging current in response to a charging temperature associated with one or both of the firstplug and second temperature sensorsthe adapter exceeding a threshold charging temperature.
In at least one approach, a vehicle charger assembly is provided. The vehicle charger assembly may include a plug including a first temperature sensor, and an adapter mechanically and electrically couplable to the plug and including a second temperature sensor. The vehicle charger assembly may further include a charge circuit interrupting device adapted to effect a signal to the first and second temperature sensors. The charge circuit interrupting device may further be adapted to terminate a charging current responsive to receiving a feedback signal indicative of an average of temperatures at the first and second temperature sensors exceeding a threshold temperature.
Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
Referring to
The charger assembly 10 may include a vehicle coupler 30, a circuit-interrupter 32 such as a charge circuit interrupting device (CCID), a plug 34, and an adapter 36. The vehicle coupler 30 may be a plug that interfaces the charging port 20 of the vehicle 12. By way of example, the coupler 18 can comprise a power link and communications interface that conforms to Society of Automotive Engineers (SAE) Electric Vehicle and Plug-in Hybrid Electric Vehicle Conductive Charge Coupler standard (J1772), hereinafter “SAE J1772.” The SAE J1772 standard provides a procedure for coupling an EV to an EVSE and for establishing and confirming connection between a high voltage link at an EV and a high voltage link at an EVSE.
A first wiring conduit 40 may extend between the vehicle coupler 30 and the circuit-interrupter 32 (e.g., from the vehicle coupler 30 to the circuit-interrupter 32). One or more components may be disposed between the vehicle coupler 30 and the circuit-interrupter 32 such that the first wiring conduit 40 does not directly engage the vehicle coupler 30, the circuit-interrupter 32, or either the vehicle coupler 30 or the circuit-interrupter 32.
A second wiring conduit 42 may extend between the circuit-interrupter 32 and the plug 34 (e.g., from the circuit-interrupter 32 to the plug 34). One or more components may be disposed between the circuit-interrupter 32 and the plug 34 such that the second wiring conduit 42 does not directly engage the circuit-interrupter 32, the plug 34, or either the circuit-interrupter 32 or the plug 34.
The charger assembly 10 may be configured such that either the plug 34 of the adapter 36 may be plugged into an outlet 50. The outlet 50 may be, for example, a wall outlet disposed on a wall 52. In this way, the outlet 50 may be installed in or on a wall 52 of a garage or other structure. In some applications, the outlet 50 may include a standard or conventional 110 VAC electrical socket. In still other applications, the outlet 50 may include a 220 VAC electrical socket. In still other applications, the outlet 50 may include both a 110 VAC electrical socket and a 220 VAC electrical socket.
Referring to
The plug 34 may be a 120 VAC plug, and may be a NEMA 5-15 connector. In this way, the plug 34 may permit Level 1 charging. Such plugs may allow drivers to charge wherever a suitable outlet is available. A Level 1, 120 VAC charger may provide, for example, 16 amps or 1.92 kW, and may add, for example, two to five miles of electric range for every hour of charging.
The adapter 36 may include an adapter housing 70. The adapter housing 70 may include or define a receptacle 72 that may be adapted to receive at least a portion of the plug 34. For example, the receptacle 72 may receive the power prongs 66 and the ground prong 68 such that the plug 34 may be mechanically and electrically coupled to the adapter 36. The adapter 36 may further include a prong interface 74.
The prong interface 74 may include one or more prongs disposed in a suitable arrangement. For example, the prongs may be disposed in an arrangement corresponding to a NEMA 14-30 arrangement (e.g., as shown in
In this way, the adapter may permit Level 2 charging. A Level 2, 240 VAC charger may provide, for example, 80 amps or 19.2 kW, and may add, for example, ten to 25 miles of electric range for every hour of charging.
Referring again to
The adapter 36 may also include at least one thermal sensor 82. The thermal sensor 82 may be provided in the adapter housing 70. The thermal sensor 82 may also include a device or material that is capable of sensing an elevation in temperature inside the adapter housing 70. In at least one approach, the thermal sensor 82 may include at least one thermistor, that may include a ceramic or polymer material.
Referring to
The charger assembly 100 may include a plug 34 and an adapter 36. The adapter 36 may be mechanically and electrically couplable to the plug 34. The plug 34 may include a first temperature sensor 80, and the adapter 36 may include a second temperature sensor 82. In at least one approach, the first temperature sensor 80 is a first thermistor, and the second temperature sensor 82 is a second thermistor. One or both of the first and second temperature sensors 80, 82 may be a ceramic or polymer material.
The charger assembly 100 may further include a circuit-interrupter 32 such as a charge circuit interrupting device (CCID). The circuit-interrupter 32 may be in electrical communication with the plug 34 and the adapter 36. The circuit-interrupter 32 may be adapted to reduce a charging current in response to a charging temperature associated with one or both of the first and second temperature sensors 80, 82 exceeding a threshold charging temperature. As used herein, a temperature (or average temperature, or other temperature function) “exceeds” the threshold charging temperature when the temperature elevates above the threshold charging temperature. Reduction of the charging current may include reducing the charging current from a first amperage to a second amperage that is less than the first amperage. The second amperage may be such that the plug (or plug and receptacle) interfaces of the plug 34 and the adapter 36 may reduce over time. In at least one approach, the second amperage is zero amps such that the charging current through the charger assembly 100 is terminated.
The circuit-interrupter 32 may be electrically connected to the power prongs 66, as indicated by dashed line 102, and may be electrically connected to the ground prong 68, as indicated by dashed line 104.
The circuit-interrupter 32 may be adapted to effect a thermocouple signal to the first temperature sensor 80, the second temperature sensor 82, or both the first and second temperature sensors 80, 82. As such, the circuit-interrupter 32 may be adapted to effect a thermocouple signal to at least the first temperature sensor 80, as indicated by dashed line 106. The circuit-interrupter 32 may further be adapted to receive a thermocouple feedback signal to the first temperature sensor 80, the second temperature sensor 82, or both the first and second temperature sensors 80, 82. As such, the circuit-interrupter 32 may be adapted to receive a thermocouple feedback signal to at least the first temperature sensor 80, as indicated by dashed line 108.
As shown in the approach of
Referring now to
The circuit-interrupter 32 may further include a decoder 126 that may be disposed within the circuit-interrupter 32 housing. The decoder 126 may be in electrical communication with the encoder 122, as indicated by dashed line 128. In this way, the circuit-interrupter 32 (e.g., at the decoder 26) may be adapted to receive the signal indicative of a temperature at the second temperature sensor 82. In this way, the circuit-interrupter 32 may be adapted to reduce the charging current in response to the temperature at the first temperature sensor 80, the second temperature sensor 82, or at both the first and second temperature sensors 80, 82 exceeding the threshold temperature.
Referring now to
In at least one approach, a method for controlling vehicle charging is provided. The method may include, at a charge circuit interrupting device (CCID) that is electrically connected to a plug and an adapter electrically connected to the plug, monitoring a first charging temperature in the plug and a second charging temperature in the adapter. The method may further include, at the CCID, reducing a charging current in response to a charging temperature associated with one or both of the first and second temperature sensors exceeding a threshold charging temperature.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes may include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.
