Plug-in electric vehicle supply equipment having a process and device for circuit testing

• US 9,013,206 B2
• Filed: 05/31/2012
• Issued: 04/21/2015
• Est. Priority Date: 05/31/2012
• Status: Active Grant

• Current Assignee: Bosch Automotive Service Solutions, Inc. (Robert Bosch GmbH)
• Original Assignee: Bosch Automotive Service Solutions, Inc. (Robert Bosch GmbH)
• Inventors: Muller, Michael, Yankitis, Charles K., Futkos, David P., Schuping, Matthew C.
• Primary Examiner(s): Baldridge, Benjamin M
• Application Number:
  US13/485,116
• Publication Number:
  US 20130321024A1
• Time in Patent Office: 1,055 Days
• Field of Search: 324/764.01
• US Class Current: 324/764.01
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/80 Time limits
• 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 53/14 Conductive energy transfer
• CPC Class Codes: B60L 53/18 Cables specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/305 Communication interfaces
• CPC Class Codes: B60L 53/51 Photovoltaic means
• CPC Class Codes: B60L 53/52 Wind-driven generators
• CPC Class Codes: B60L 53/65 involving identification of vehicles or their battery types
• CPC Class Codes: G01R 31/327 Testing of circuit interrupters, switches or circuit-breakers
• CPC Class Codes: G01R 31/40 Testing power supplies testing photovoltaic devices H02S50/10
• 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 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y02T 90/167 Systems integrating technologies related to power network operation and communication or information technologies for supporting the interoperability of electric or hybrid vehicles, i.e. smartgrids as interface for battery charging of electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: Y04S 30/14 Details associated with the interoperability, e.g. vehicle recognition, authentication, identification or billing

Abstract

A system for connecting an electric vehicle to a high voltage power source is disclosed. The system including an electric vehicle supply equipment (EVSE) having an electrical plug compatible with a high voltage power outlet, the plug connected to a power cord. The power cord is connected to a housing containing a number of electrical components configured to control the power flow to an electric vehicle to recharge the vehicle'"'"'s batteries. The power cord extends from the housing and is connected to a standard electric vehicle connector compatible with battery electric vehicles (BEV) and plug-in hybrid electric vehicles (PHEV). The EVSE further includes safety measures, such as a relay that controls the flow of power to the vehicle connector, a ground fault interrupter, and a circuit tester to protect users from high voltage electric shocks.

Claims

1. An apparatus for connecting an electric vehicle to an electrical socket, comprising:

a socket connector configured to couple with the electrical socket;

a power conduit connected to the socket connector and configured to convey a voltage from the electrical socket;

a power control device connected to the power conduit and configured to control a delivery of power through the power conduit, wherein the power control device includes an electrical relay that bridges portions of the power conduit;

a vehicle connector connected to the power conduit and configured to connect to the electric vehicle;

a sensor configured to sense voltage, current, or configuration of the power control device, wherein sensing further includes counting a sinusoidal voltage to determine if the electrical relay is opened or closed; and

a processor configured to test at least the power control device and determine functioning status of the power control device based on an output of the sensor, wherein the processor is configured to test the operation of the electrical relay by actuating the electrical relay multiple times.

2. The apparatus of claim 1, wherein the processor is also configured to test the operation of the electrical relay by sensing a flow of current across a contact of the electrical relay.

3. The apparatus of claim 1, wherein the processor is configured to test the operation of the relay by actuating the electrical relay and sensing a physical position of the electrical relay.

4. The apparatus of claim 3, wherein the processor is configured to allow operation or disable operation of the apparatus based on the test.

5. The apparatus of claim 1, wherein the processor is configured to allow operation or disable operation of the apparatus based on the test.

6. An apparatus for connecting an electric vehicle to a high voltage electrical socket, comprising:

means for coupling with the high voltage electrical socket;

means for conveying a current from the high voltage electrical socket that is connected to the means for coupling;

means for controlling current flow or magnitude along the means for conveying the current;

means for interrupting the flow of current to prevent electric shock;

means for connecting to the electric vehicle that is connected to the means for conveying the current, the means for connecting bridges portions of the means for conveying;

means for sensing at least one of voltage, current, or configuration of the means for controlling, wherein means for sensing further counts a sinusoidal voltage to determine if the means for connecting is opened or closed; and

means for testing at least the means for connecting and determining functioning status of the means for connecting based on the means for sensing, wherein the means for testing tests the operation of the means for connecting by actuating the means for connecting multiple times.

7. The apparatus of claim 6, wherein the means for interrupting includes an auto-reset function that restores the current flow.

8. The apparatus of claim 6, wherein the means for testing tests the operation of the means for connecting by sensing the flow of current across a contact of the means for connecting.

9. The apparatus of claim 6, wherein the means for testing tests the operation of the means for connecting by actuating the means for connecting and sensing a physical position of the means for connecting.

10. The apparatus of claim 6, wherein the means for testing allows operation or disables operation of the apparatus based on the testing.

11. A method of charging an electrical vehicle, comprising the steps of:

receiving a high electrical voltage from a power source;

conducting the voltage from the power source to the electrical vehicle via a power conduit;

controlling the voltage flowing on the power conduit with a switching relay;

cutting power to the electrical vehicle with a breaker circuit;

sensing at least one of voltage, current, or configuration associated with the switching relay, wherein sensing further includes counting a sinusoidal voltage to determine if the switching relay is opened or closed; and

testing the switching relay and determining functioning status of the switching relay based on the sensing, wherein testing tests an operation of the switching relay by actuating the switching relay multiple times.

12. The method of claim 11, wherein testing tests the operation of the switching relay by actuating the switching relay and by sensing the flow of current across a contact of the switching relay.

13. The method of claim 11, further comprising allowing operation or disabling operation of charging based on the test.