Patent Application
20240246441
This invention relates generally to electric vehicle charging, and more particularly, embodiments of the invention relate to systems and methods for interrupting a charging circuit of electric vehicle.
Reliable, efficient and timely charging is needed to charge an electric vehicle battery. Typically, in order to provide charging that is reliable, efficient, and timely, charges are designed with a high current draw. However, such chargers tend to result in a residential service overload condition. In order to avoid residential service overload, many residences require an upgrade to a residential electric system. For example, in some instances it may be necessary to upgrade the electrical panel in order to adequately accommodate a level 2 (e.g., 7-11 kW) electric vehicle charger that would require 40-60 amps.
Various solutions have been sought in order to make residential charging less expensive so that more customers will use electric vehicles. In some instances, the associated cost associated with necessary electrical upgrades to service electric vehicle chargers may discourage some individuals from purchasing electric vehicles.
Shortcomings of the prior art are overcome and additional advantages are provided through the provision of an electrical system that includes a first circuit configured to facilitate regulating an electric current to an electric vehicle charger that is electrically coupled to an electrical control switch, where the electrical control switch may be preferentially dedicated to an electrical device. The first circuit includes the electrical control switch, a power distribution block, a first compact circuit protector, a current transformer, and the electrical device, that are electrically coupled via a conductor. Further, the conductor feeds back to the electrical control switch from the current transformer to complete the first circuit. Additionally, the power distribution block is configured to split the electric current received from the electrical control switch to the first compact circuit protector, a second compact circuit protector and a third compact circuit protector. The electrical system also includes a second circuit that electrically couples the second compact circuit protector to a contactor and the electric vehicle charger. Further, the second circuit is configured to transmit, via the contactor, the electric current received by the power distribution block to the electric vehicle charger, where the contactor has a default position that is closed to complete the second circuit. Additionally, the third compact circuit protector includes a control circuit configured to receive, via a third circuit and based on the current transformer detecting a current draw flowing therethrough, an electrical input from the current transformer. The control circuit is configured to propagate, based on receiving the electrical input, a signal to the contactor to switch open, thereby interrupting the electric current to the electric vehicle charger.
Also disclosed herein is an electrical system that includes a first electrical circuit configured to transmit an electric current from an electrical control switch to a power distribution block. The power distribution block is configured to split the electric current to, in part, a current transformer via a first compact circuit protector. Further, the current transformer is configured to further transmit the electric current to an electrical device. A second electrical circuit configured to further transmit the electric current that is split from the power distribution block, where the electric current is split, via a second compact circuit protector, to a contactor that has a default position that is closed to further transmit the electric current to an electric vehicle charger.
A method of interrupting an electric circuit is provided. The method includes receiving, by a control circuit of an electrical system, an electrical input from a current transformer, where the current transformer is electrically coupled to a transformer sensor configured to detect an electrical load flowing through the current transformer. Further, the electrical load flowing through the current transformer is transmitted, via a conductor and based on an electrical device being activated, to the electrical device. The method further includes transmitting, by the control circuit, an electrical signal from the control circuit to a contactor, where the contactor includes separable contacts having a closed default position and configured to open based on receiving the electrical signal and the opening of the separable contacts interrupts the current flow to an electric vehicle charger.
Additional features and advantages are realized through the concepts described herein.
One or more aspects are particularly pointed out and distinctly claimed as examples in the claims at the conclusion of the specification. The foregoing as well as objects, features, and advantages of one or more aspects are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
Aspects of the present invention and certain features, advantages, and details thereof are explained more fully below with reference to the non-limiting examples illustrated in the accompanying drawings. Descriptions of well-known processing techniques, systems, components, etc. are omitted so as to not unnecessarily obscure the invention in detail. It should be understood that the detailed description and the specific examples, while indicating aspects of the invention, are given by way of illustration only, and not by way of limitation. Various substitutions, modifications, additions, and/or arrangements, within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure. Note further that numerous inventive aspects and features are disclosed herein, and unless inconsistent, each disclosed aspect or feature is combinable with any other disclosed aspect or feature as desired for a particular embodiment of the concepts disclosed herein.
The terms “couple,” “coupled,” “couples,” “coupling,” and the like should be broadly understood to refer to connecting two or more elements or signals electrically and/or mechanically, either directly or indirectly through intervening circuitry and/or elements. Two or more electrical elements may be electrically coupled. Two or more electrical elements may be electrically coupled, either direct or indirectly, but not be mechanically coupled; two or more mechanical elements may be mechanically coupled, either direct or indirectly, but not be electrically coupled; two or more electrical elements may be mechanically coupled, directly or indirectly, but not be electrically coupled. Coupling (whether only mechanical, only electrical, or both) may be for any length of time, e.g., permanent or semi-permanent or only for an instant. “Electrically coupled” and the like should be broadly understood and include coupling involving any electrical signal, whether a power signal, a data signal, and/or other types or combinations of electrical signals.
Disclosed herein is an electrical system that includes a first circuit configured to facilitate regulating an electric current to an electric vehicle charger that is electrically coupled to an electrical control switch that is preferentially dedicated to an electrical device. The first circuit includes the electrical control switch, a power distribution block, a first compact circuit protector, a current transformer, and the electrical device electrically coupled (e.g., in series) via a conductor. Further, the conductor feeds back to the electrical control switch from the current transformer to complete the first circuit. Additionally, the power distribution block is configured to split the electric current received from the electrical control switch to the first compact circuit protector, a second compact circuit protector and a third compact circuit protector. The electrical system also includes a second circuit that electrically couples the second compact circuit protector to both a contactor and the electric vehicle charger. The second circuit is configured to transmit, via the contactor, the electric current received by the power distribution block to the electric vehicle charger, where the contactor has a default position that is closed to complete the second circuit. Additionally, the third compact circuit protector includes a control circuit configured to receive, via a third circuit and based on the current transformer detecting a current draw flowing therethrough, an electrical input from the current transformer, and based thereon propagate a signal to the contactor to switch open, thereby interrupting the electric current to the electric vehicle charger.
In particular, this advantage is realized through the use of the electrical control panel 110 includes the electrical control switch 112 that is shared with both the electric vehicle charger 150 and an electrical device (not shown) that has a high current rating such as, for example, a thermostatically controlled device. For instance, according to one embodiment, the thermostatically controlled device may include a residential appliance (e.g., a stovetop, oven, and/or range).
According to an implementation of the present disclosure, the example electrical system 100 may only increase the load to the electrical control panel 110 based on the amperage differential at the electrical control switch 112 between the electrical device (not shown) and the electric vehicle charger 150. According to various embodiments, the amperage differential could be, for example, about 0 amps to about 40 amps depending upon the amperage of the electrical device (not shown) and the electric vehicle charger 150. As disclosed herein the electrical system 100 may eliminate the need to replace the electrical control panel 110, thereby providing cost savings, but the electrical control switch 112 may need to be replaced in order to accommodate both the electrical device (not shown) and the electric vehicle charger 150 based on the associated amperage differential. The electrical control panel 110 may have size limitations depending upon the specific manufacturer limitations such as, for example, a limitation of about 70 amp to 100 amp limitation per bus stab/finger that receives the electrical control switch 112.
The EV saver 102 includes a power distribution block 130 that is electrically coupled to and fed from the electrical control switch 112. The power distribution block 130 is configured to split the electric current received from the electrical control switch 112. The power distribution block 130 may include, according to various embodiments, multiple finger-safe power distribution blocks ganged together. In particular, the finger-safe power distribution blocks may include two Bussmann series panel mount fuse blocks such as the PDBFS330 (380 amp fuse block) and PDBFS204 (175 amp fuse block) by Eaton Corporation of St. Louis, Missouri. The multiple finger-safe power distribution blocks may facilitate connection to a phase conductor sized up to about 100 amp. As described herein, a conductor may include such diverse members as an electrical cable, a wire (either stranded or solid), a grounding plate, an inductive shield, a bus bar, or an electricity-transmitting path formed of a conductive film deposited on an insulating plate or panel, etc.
The power distribution block 130 splits the electric current to a plurality of compact circuit protectors (CCPs). In particular, the power distribution block 130 is electrically coupled to and splits the electric current to a first compact circuit protector 120, a second compact circuit protector 122, and a third compact circuit protector 124. The CCPs may be overcurrent devices for a particular current range.
According to various embodiments, the first compact circuit protector 120 may include a first two-pole device configured to take a first fuse rated from about 35 amps to about 60 amps, which likely corresponds to the load of the electrical device (not shown). Further, the second compact circuit protector 122 may include a second two-pole device configured to take a second fuse having a rating that is based on the amperage demand of the electric vehicle charger 150. According to various embodiments, the second compact circuit protector may be sized to a specific amperage demand. For instance, if the load from the electric vehicle charger 150 were about 25 amps then the second compact circuit protector 122 selected may include a current rating of about 30 amps because it takes fuses from about 1 amp to about 30 amps. Similarly, if the load from the electric vehicle charger 150 were about 50 amps, then the second compact circuit protector 122 selected may include a current rating of about 60 amps because it takes fuses having a rating from about 35 amps to about 60 amps. In one embodiment, if the load from the electric vehicle charger 150 were 80 amps, then the second compact circuit protector 122 selected may include a current rating of about 100 amps because it takes fuses having a rating from about 70 amps to about 100 amps. The advantage to adapting the second compact circuit protector 122 to the amperage demand of the electric vehicle charger 150 is that it would be fine-tuned to match actual loads and only a limited number of EV saver 102 device options would need to be made available to consumers in the marketplace.
According to various embodiments, the third compact circuit protector 124 may include a single-pole device configured to take a third fuse having a current rating of about 30 amp that takes fuses from about 1 amp to about 30 amps. Additionally, the third compact circuit protector 124 serves as the control circuit for the EV saver 102.
The EV saver 102 further includes a current transformer 116 electrically coupled to the first compact circuit protector 120. In particular, the current transformer 116 may be configured such that the conductor(s) fed from the first compact circuit protector 120 pass through the current transformer 116. The current transformer 116 is configured to detect a current draw flowing therethrough and based thereon transmit an electrical input to a contactor 140 of the EV saver 102. The current draw that the current transformer 116 detects would result from a load demand from the electrical device (not shown) in response to the electrical device being activated or otherwise turned on. For example, if the electrical control switch 112 is electrically coupled to both an oven and a user turns the oven on to bake a food item, for instance, then the activation of the oven would cause the current transformer 116 to detect a load demand from the oven and transmit the electrical input to the third compact circuit protector 124. The conductor(s) fed from the first compact circuit protector 120, which pass through the current transformer 116, feed back to the electrical control switch 112 from the current transformer 116 to complete the associated circuit connection.
As referenced in the preceding paragraph, the EV saver 102 also includes a contactor 140. The contactor 140 is electrically coupled to and fed, via a conductor, by the second compact circuit protector 122. As described herein, a contactor 140 includes any electricity-conducting component of an electrical connector, including a contact surface intended to form a readily made and broken electricity-conducting joint by directly engaging either a conductor or a corresponding surface of a cooperating joint-forming conductive component, so as to permit the passage of electricity through the joint from one component to the other. According to one embodiment, the contactor 140 may include an electromagnetic coil and separable contacts, where the electromagnetic coil is configured to cause the separable contacts to open in response to receiving the signal from the control circuit of the third compact circuit protector 124. According to one embodiment, the separable contacts may include an electrical contact and additional supporting structure that is specially adapted to make with a specific complementary electrical contact. The separable contacts are a coupling part or electrically coupling part that includes a contact and a counter-contact.
In particular, the joint-forming conductive component of the contactor 140 includes separable contacts having a closed default position. The example electrical system 100 is preferentially dedicated to the electrical device such that when the electrical device (not shown) is activated, the control circuit of the third compact circuit protector 124 would energize the contactor 140 so that the contactor 140 opens to reduce the likelihood that the electrical control switch 112 gets overloaded from having a load from both the electric vehicle charger 150 and the electrical device (not shown). Thus, upon receiving a signal from the third compact circuit protector 124, the separable contacts are opened, thereby interrupting the current flow to an electric vehicle charger 150 resulting in non-coincidental loads of the electric vehicle charger 150 and the electrical device (not shown). Conversely, since the separable contacts of the contactor 140 have a closed default position, when the electrical device (not shown) is not activated, the contactor 140 would not be energized and current would be fed to the electric vehicle charger 150 to facilitate charging an electric vehicle.
According to various embodiments, the disclosed electrical system 100 may be programmed to delay charging the electric vehicle for a predetermined amount of time after the current transformer 116 stops detecting the load demand from the electrical device (not shown). For instance, once the load demand is no longer detected by the current transformer 116, the control circuit of the third compact circuit protector 124 may continue to energize the contactor 140, (e.g., via an electromagnetic coil) so that the separable contacts remain open for the predetermined amount of time (e.g., 20 minutes). If the electrical device (not shown) is an oven, for example, the predetermined amount of time may allow for the oven to be activated periodically or irregularly (e.g., every 2-3 minutes) to maintain a desired temperature without having to be constantly activated during baking in order to maintain preference or priority of current flow in the electrical system 100. Various other advantages are also contemplated and may be obtained by delaying the closure of the separable contacts. The predetermined amount of time may be, according to one embodiment, customizable by the user. Once the electrical device (not shown) has been idle and the load demand has not been detected by the current transformer 116 for the predetermined amount of time then the control circuit of the third compact circuit protector 124 may stop energizing the contactor 140.
The power distribution block 230 is configured to split the electric current received from the electrical control switch 212 to the first compact circuit protector 220, a second compact circuit protector 222 and a third compact circuit protector 224. The second compact circuit protector 222 is included in a second circuit 206 that electrically couples the second compact circuit protector 222 to a contactor 240 and the electric vehicle charger 250. The second circuit 206 is configured to transmit, via the contactor 240, the electric current received by the power distribution block 230 to the electric vehicle charger 250. When closed, the contactor 240 completes the second circuit 206 to facilitate charging the electric vehicle battery 252.
The third compact circuit protector 224 includes a control circuit 226 configured to receive, via a third circuit (see
According to one embodiment, the control circuit 226 may include an integrated wiring arrangement configured to electrically couple a plurality of input terminals to a plurality of output terminals to facilitate electrical current flow.
In step 302, the control circuit of an electrical system receives an electrical input from a current transformer, where the current transformer is electrically coupled to a transformer sensor configured to detect an electrical load flowing through the current transformer. Further, the electrical load flowing through the current transformer is transmitted to the electrical device via a conductor in response to the electrical device being activated.
In step 304, the control circuit transmits an electrical signal from the control circuit to a contactor, where the contactor includes separable contacts having a closed default position that are configured to open based on receiving the electrical signal. Once the separable contacts open, current flow to an electric vehicle charger is interrupted.
According to various embodiments, the control circuit of the electrical system may be electrically coupled to an electrical control switch configured to transmit an electrical current to a power distribution block, where the power distribution block is configured to split the electrical current to a first compact circuit protector, a second compact circuit protector, and a third compact circuit protector, where the third compact circuit protector comprises the control circuit.
Additionally, according to various embodiments, the first compact circuit protector may be configured to transmit the electrical current that is split by the power distribution block to the current transformer, where the first compact circuit protector includes a first two-pole device, and where the first two-pole device includes a first fuse rated from about 35 amps to about 60 amps.
According to various embodiments, the second compact circuit protector is configured to transmit the electrical current that is split by the power distribution block to the contactor, where the second compact circuit protector includes a second two-pole device, and where the second two-pole device includes a second fuse having rating that is based on amperage demand of the electric vehicle charger.
In one embodiment, the method 300, may include another step (not shown) that includes disrupting, by the control circuit and based on the electrical device being deactivated, transmission of the electrical signal to the contactor, wherein the disrupting facilitates returning the separable contacts to the closed default position thereby causing the current flow to propagate through the contactor to the electric vehicle charger.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), and “contain” (and any form contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a method or device that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of a device that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features. Furthermore, a device or structure that is configured in a certain way is configured in at least that way, but may also be configured in ways that are not listed.
The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below, if any, are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of one or more aspects of the invention and the practical application, and to enable others of ordinary skill in the art to understand one or more aspects of the invention for various embodiments with various modifications as are suited to the particular use contemplated.
