Electric vehicle supply equipment with over-current protection

• US 8,633,678 B2
• Filed: 05/10/2011
• Issued: 01/21/2014
• Est. Priority Date: 05/10/2011
• Status: Active Grant

• Current Assignee: Leviton Manufacturing Company Incorporated
• Original Assignee: Leviton Manufacturing Company Incorporated
• Inventors: Yegin, Sural, Ramirez, Carlos E., Soto, Victor, Brown, Kenneth J.
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US13/104,738
• Publication Number:
  US 20120286729A1
• Time in Patent Office: 987 Days
• Field of Search: 320/107, 320/109, 320/134, 320/136, 361/31, 361/79, 361/93.9
• US Class Current: 320/134
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 2250/16 by display
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: H02H 3/006 Calibration or setting of parameters
• CPC Class Codes: H02H 3/093 with timing means in general H02H3/027; thermal delay H02H3/085; timing means for undervoltage protection H02H3/247
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

An EVSE system includes an electric vehicle supply circuit having overcurrent protection circuit to prevent excessive current from flowing to the electric vehicle. A current limit may be set by a manufacturer of the EVSE, by a user of the EVSE, by an electric utility, by the EVSE itself in response to a control pilot signal, etc. The current limit may be set to prevent tripping an overcurrent protection device on a branch circuit for the EVSE, to accommodate one or more parameters of an electric vehicle charging facility, etc. The overcurrent protection feature may be integrated into a controller for the electric vehicle supply circuit, or it may be operate independently of the controller.

Claims

1. An electric vehicle supply circuit comprising:

a charge circuit interrupting device to interrupt a flow of current from a power source to an electric vehicle;

a controller coupled to the charge circuit interrupting device, where the controller is constructed and arranged to control the charge circuit interrupting device in response to a control pilot signal from the electric vehicle; and

an overcurrent protection circuit including a current sensor coupled to the controller, the controller constructed and arranged to prevent excessive current from flowing to the electric vehicle by controlling the charge circuit interrupting device in response to the current sensor.

2. The electric vehicle supply circuit of claim 1 where the controller is constructed and arranged to open the charge circuit interrupting device when the current exceeds a limit for a first predetermined period of time.

3. The electric vehicle supply circuit of claim 2 where the controller is constructed and arranged to close the contactor after a second predetermined period of time.

4. The electric vehicle supply circuit of claim 2 where the controller is constructed and arranged to close the contactor after receiving a manually generated reset input.

5. The electric vehicle supply circuit of claim 1 where the controller is constructed and arranged to implement a trip curve.

6. The electric vehicle supply circuit of claim 1 where the overcurrent protection circuit is constructed and arranged to open the charge circuit interrupting device substantially independently of the controller.

7. The electric vehicle supply circuit of claim 6 where the controller is constructed and arranged to perform a supervisory function for the overcurrent protection circuit.

8. The electric vehicle supply circuit of claim 1 where the overcurrent protection circuit operates in response to a current limit set by a manufacturer.

9. The electric vehicle supply circuit of claim 1 where the overcurrent protection circuit is constructed and arranged to operate in response to a current limit that is coordinated with the control pilot signal.

10. The electric vehicle supply circuit of claim 1 where the overcurrent protection circuit is constructed and arranged to operate in response to a current limit input by a user.

11. The electric vehicle supply circuit of claim 1 further comprising an alarm constructed and arranged to operate in response to the overcurrent protection circuit.

12. A method comprising:

supplying electric power to an electric vehicle through an electric vehicle supply circuit that is fed by a branch circuit;

monitoring the current flowing to the vehicle through the electric vehicle supply circuit using a current sensor;

preventing excessive current from flowing to the electric vehicle by interrupting the flow of current to the electric vehicle if the current flowing to the vehicle exceeds a limit as detected by the current sensor; and

setting the limit to prevent the electric vehicle supply circuit from tripping an overcurrent protection device on the branch circuit.

13. The method of claim 12 further comprising:

coupling the electric vehicle supply circuit to an electric vehicle charging facility; and

setting the current limit in response to a parameter of the electric vehicle charging facility.

14. The method of claim 12 further comprising activating an alarm if the current flowing to the vehicle exceeds the limit.

15. The method of claim 12 further comprising automatically testing the overcurrent protection device.

16. A system comprising:

an electric vehicle supply circuit having an overcurrent protection feature to interrupt the flow of current from a power source to an electric vehicle if the current flowing to the electric vehicle exceeds a limit; and

an interface to input the limit to the electric vehicle supply circuit.

17. The system of claim 16 where the interface comprises a manual user interface.

18. The system of claim 16 where the interface comprises an automatic interface.

19. The system of claim 18 where the automatic interface is constructed and arranged to receive a demand response signal from a utility.

20. An electric vehicle supply circuit comprising:

a charge circuit interrupting device to interrupt a flow of current from a power source to an electric vehicle;

a controller coupled to the charge circuit interrupting device, where the controller is constructed and arranged to control the charge circuit interrupting device in response to a control pilot signal from the electric vehicle;

a metering circuit; and

an overcurrent protection circuit constructed and arranged to prevent excessive current from flowing to the electric vehicle, where the overcurrent protection circuit is constructed and arranged to operate in response to the metering circuit.

21. An electric vehicle supply circuit comprising:

a charge circuit interrupting device to interrupt a flow of current from a power source to an electric vehicle;

a controller coupled to the charge circuit interrupting device, where the controller is constructed and arranged to control the charge circuit interrupting device in response to a control pilot signal from the electric vehicle; and

an overcurrent protection circuit constructed and arranged to prevent excessive current from flowing to the electric vehicle, the overcurrent protection circuit constructed and arranged to open the charge circuit interrupting device substantially independently of the controller.

22. An electric vehicle supply equipment comprising:

an enclosure including;

an electric vehicle supply circuit for providing a flow of current to an electric vehicle from a power source;

a charge circuit interrupting device located in the enclosure, the charge circuit interrupting device interrupting the flow of current from the power source to the electric vehicle;

a controller located in the enclosure, the controller being coupled to the charge circuit interrupting device, where the controller is constructed and arranged to control the charge circuit interrupting device; and

an overcurrent protection circuit located in the enclosure, the overcurrent protection circuit including a current sensor coupled to the controller, the controller constructed and arranged to prevent excessive current from flowing to the electric vehicle by controlling the charge circuit interrupting device in response to the current sensor.

23. The electric vehicle supply equipment of claim 22, wherein the overcurrent protection circuit comprises an overcurrent protection circuit integral with the controller.

24. The electric vehicle supply equipment of claim 23, wherein the overcurrent protection circuit utilizes the current sensor, and the current sensor is coupled to the controller.

25. The electric vehicle supply equipment of claim 22, wherein the overcurrent protection circuit comprises an overcurrent protection circuit separate from the controller.

26. The electric vehicle supply equipment of claim 22, wherein the overcurrent protection circuit comprises an overcurrent protection circuit partially integral with the controller.

27. The electrical vehicle supply equipment of claim 22, further comprising a metering circuit to measure current flowing to an electric vehicle.

28. The electrical vehicle supply equipment of claim 22, wherein the overcurrent protection circuit operates in response to a current limit that is set by the manufacturer of the electrical vehicle supply equipment.

29. The electrical vehicle supply equipment of claim 22, wherein the overcurrent protection circuit operates in response to a current limit that is set manually via a user interface incorporated into the electrical vehicle supply equipment.

30. The electrical vehicle supply equipment of claim 29, wherein the user interface includes a wireless interface to enable a user to input the current limit through a wireless connection via a computer or smart phone.

31. The electrical vehicle supply equipment of claim 29, wherein the user interface includes a wireless interface to enable a local utility to set the current limit.

32. The electrical vehicle supply equipment of claim 31, wherein local utility sets the current limit based on time-of-day, demand response, or off-peak utility rates.

33. The electrical vehicle supply equipment of claim 29, wherein the user interface includes a potentiometer or alphanumeric display with menu-driven buttons to enable a user to input one or more current limits.

34. The electrical vehicle supply equipment of claim 22, wherein the overcurrent protection circuit operates in response to a current limit that is provided by an energy management system or an electric utility.

35. The electrical vehicle supply equipment of claim 22, wherein the overcurrent protection circuit operates in response to a current limit that is coordinated with a charging capacity of the electrical vehicle supply equipment as indicated by a control pilot signal.

36. The electrical vehicle supply equipment of claim 22, wherein the overcurrent protection circuit further includes an alarm feature that activates when the current has been or will be interrupted.