WO2012078921A2

WO2012078921A2 - Electric vehicle charger diagnostic extension cable

Info

Publication number: WO2012078921A2
Application number: PCT/US2011/064021
Authority: WO
Inventors: Robert Thomas Litjen; Hieu N. Tran; Jr. Taras Kiceniuk; Eric Dunn; Nader Lotfy
Original assignee: Aerovironment, Inc.
Priority date: 2010-12-08
Filing date: 2011-12-08
Publication date: 2012-06-14
Also published as: WO2012078921A3

Abstract

An electric vehicle ("EV") charging cable apparatus is disclosed that includes a charging cable segment (300) having first and second ends (305, 310), the charging cable segment having a power line segment (610) and a data line segment (620, 630, 635, 640, 645, 650); a first element (600) disposed at the first end of the charging cable segment, the first element configured to receive a direct current (DC) electric vehicle connector; a DC electric vehicle connector (605) disposed at the second end of the charging cable segment; and a tap coupled to at least one of the power line segment and the data line segment (320) so that the at least one of the power line segment and the data line segment are tapped for external access.

Description

DESCRIPTION

TITLE: Electric Vehicle Charger Diagnostic Extension Cable

INVENTORS: Robert Litjen, Hieu Tran, Taras Kiceniuk, Jr., Eric Dunn, and Nader Lotfy

CROSS REFERENCE TO RELATED APPLICATIONS:

This application claims the benefit of U.S. Provisional Application No. 61/421,020 filed December 8, 2010, and U.S. Provisional Application No. 61/438,213 filed January 31, 2011, the disclosure of which is incorporated by reference herein for all purposes.

TECHNICAL FIELD

This invention relates to electric vehicle equipment and accessories, and more particularly to test equipment for electric vehicles. BACKGROUND

Electric vehicles (EVs) having chemical battery-based energy stores may be recharged via an outlet to a power grid or by electric vehicle support equipment (EVSE) charger. An EVSE charger 100 is typically sited at a fixed location and may be wired to a single phase 110 volt or 240 volt power line of alternating current (i.e., 240 VAC) for Level- 1 or Level-2 alternating current charging. The EVSE charger 100 provides grounding, ground fault protection, an EVSE charging cable 105 and vehicle connector assembly 110, and a no- load make/break interlock to prevent arcing if the connector is disconnected from an electric vehicle (EV) 115 while under charge. The EVSE charger 100 may also provide high power DC charging, and may coordinate charge permission, connection verification and charge start/stop commands through the EVSE charging cable 105 as enabled by the vehicle connector assembly 110 that may be a Society of Automotive Engineers (SAE) J 1772 connector, Japan's national standard CHAdeMO-compatible connector, or other standards- based or de facto standard EV connector and that may incorporate a high-speed

communication CAN Bus (automotive bus).

SUMMARY

Embodiments of the invention include an electric vehicle ("EV") charging cable apparatus, which comprises a charging cable segment having first and second ends, the charging cable segment having a power line segment and a data line segment, for example, a Controller Area Network (CAN) bus-compliant data line segment; a first element disposed at the first end of the charging cable, the first element configured to receive a direct current (DC) electric vehicle connector; a DC electric vehicle connector, such as a SAE J 1772- compliant connector or a CHAdeMO-compliant connector, for example, may be disposed at the second end of the charging cable; and a tap which may comprise an extension cable, which may include test equipment coupled to the cable, which may be electrically coupled to at least one of the power line segment and the data line segment, where the at least one of the power line segment and the data line segment are tapped for external access. In some embodiments a plurality of test leads may be electrically coupled to the power line segment and the data line segment through the extension cable, which may comprise a transmitter coupled to the extension cable and may further comprise a receiver for receiving transmitted electrical measurement that may be coupled to a display; the transmitter may be configured to transmit an electrical measurement of at least one of the power line segment and data line segment, where the extension cable is sufficiently long to extend to at least to the first end and the second end to facilitate trouble-shooting.

Some embodiments of the invention include a method of monitoring communications between an electric vehicle (EV) and an EV charging station, which may comprise providing power from an EV charging station to an EV through a power line segment of a charging cable segment, which may be monitored for power using the tap coupled to the power line segment that may provide data representative of the power in the power line segment to a display; sending data from an EV charging station to an EV through a data line segment of the charging cable segment; and monitoring the data line segment for the data through a tap coupled to the data line segment which may further comprise monitoring transmission rate and/or monitoring charging status. In some embodiments the method may further comprise providing the data to an extension cable and/or to test equipment through the extension cable that may be electrically coupled to the power line segment and the data line segment. The method may further comprise providing the data to a plurality of test leads electrically coupled to the data line segment through the extension cable which may transmit data associated electrical measurements of at least one of the power line segment and data line segment by displaying information representing the transmitted data on a display.

In some embodiments the invention includes an electric vehicle ("EV") charging apparatus, that comprises an EV charger; an EV electrically coupled to the EV charger through an EV charging cable, the EV charging cable comprising a power line segment and a data line segment;; an extension cable which is sufficiently long to extend to at least both ends of the EV charging cable electrically coupled to at least one of the power line segment and the data line segment; and a test equipment in communication with the at least one of the power line segment and the data line segment through an extension cable; wherein a user may monitor real-time status of at least one of power through the power line segment and data through the data line segment, which may be a Controller Area Network (CAN) bus- compliant data line segment, to evaluate the status of the EV and EV charger, troubleshoot complications and monitor various parameters. In such an embodiment, the test equipment may be in communication with the at least one of the power line segment and the data line segment through a wireless transmitter, the extension cable may be sufficiently long to extend to at least both ends of the EV charging cable, the EV charging cable may be adapted to detachably connect to an SAE J1772-compliant connector, the EV charging cable may be adapted to detachably connect to a CHAdeMO-compliant connector or the data line segment is a Controller Area Network (CAN) bus-compliant data line segment.

One embodiment of the invention includes an electric vehicle ("EV") charging apparatus which includes a charging cable segment having first and second ends, the charging cable segment having a power line segment and a data line segment; means for receiving a direct current (DC) electric vehicle connector at the first end of the charging cable segment; a DC electric vehicle connector disposed at the second end of the charging cable segment; and means for coupling to at least one of the power line segment and the data line segment; wherein the at least one of the power line segment and the data line segment are tapped for external access. The means for coupling may include an extension cable electrically coupled to the power line segment and the data line segment. In such an embodiment, the apparatus may further include a test equipment coupled to the extension cable.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and not limitation in the figures of the accompanying drawings, and in which:

FIG. 1 is a prior art depiction of an electric vehicle (EV) connected to an electric vehicle support equipment (EVSE) charger;

FIG. 2 depicts one embodiment of a charging cable segment coupled between the EV and the EVSE charger, with the charging cable segment having an electrical tap connected to test equipment; FIG. 3 depicts one embodiment of the charging cable segment;

FIGS. 4 and 5 are an element configured to receive a direct current DC electric vehicle connector and a perspective view of a direct current (DC) electric vehicle connector, respectively;

FIG. 6 is an electrical schematic depicting an exemplary charging cable segment having test leads electrically coupled to a tap;

FIG. 7 is an electrical schematic depicting an exemplary charging cable segment with test equipment coupled to an extension cable of the tap;

FIG. 8 depicts one embodiment of an EV charging cable that has an electrical tap in communication with a remote site through a detection unit;

FIG. 9 depicts one embodiment of an EV simulator casing having a diagnostic extension cable internally coupled to external ports for test;

FIG. 10 depicts one embodiment of an EV simulator having an internal diagnostic extension cable electrically coupled electrically between a level-3 charger and an EV simulator board; and

FIG. 11 is an electrical schematic of an electrical tap of power and data segments positioned between an EV simulator board and EVSE charger.

DETAILED DESCRIPTION FIG. 2 depicts an electric vehicle charger diagnostic cable extension coupled as an extension between an EVSE charging cable 105 of a free-standing electric vehicle service equipment (EVSE) charger 100 and an electric vehicle (EV) 115 to provide external access to power line and data line segments in the electrical path via an electrical tap. In one embodiment, the charger diagnostic cable extension is a charging cable segment 200 detachably coupled to the EV 115 using a standard vehicle connector assembly 110 that may be an SAE J 1772-compatible connector, CHAdeMO-compatible connector or other standards-based or de facto standard EV connector. The other end of the charging cable segment 200 may be detachably coupled to the EVSE charging cable 105 that may have an SAE J 1772-compatible connector, CHAdeMO-compatible connector or other standards- based or de facto standard connector that may be a DC electric vehicle connector. In one embodiment, the charging cable segment 200 may continue the power line and data line segments provided by the EVSE charging cable 105. For example, the power line segment may transmit electricity to the EV in the form of an electric current of 120 Amps at 300 V, levels. The data line segment may contain signal wires such as a Controller Area Network (CAN) bus-compliant data line segment and other signal wires in communication with the processors making up the EVSE charger control system (not shown). The charging cable segment may have an electrical tap 205 that may be in communication with both the power line and data line segments for external access by a user. In one embodiment, the electrical tap 205 may have an extension cable 210 to facilitate the electrical coupling of measuring equipment 215 (alternatively referred to as "test equipment") to the charging cable segment 200 through the tap 205. The measuring equipment 215 may monitor the various parameters of the electricity flow, evaluate the status of the EVSE charger 100 and EV 115, troubleshoot complications, perform maintenance, and ensure safe operating conditions.

FIG. 3 depicts an exemplary charging cable segment that has a plurality of output ports and wires as part of an electrical tap to enable monitoring low and high voltage signals transmitted through the charging cable simultaneously. The charging cable segment 300 may have: (a) a first end 305 having the docking attachment to receive the DC electric vehicle connector 110 of the Fast Charger 100; (b) a second end 310 having a DC electric vehicle connector 315, and terminals forming a plurality of output ports and wires collectively defined as a "tap" 320 that may be connected to a respective plurality power and data line segments of the cable 300. The tap 320 may then be coupled to sensors and monitoring meters such as test equipment (See FIG. 2) to obtain real-time status within both high-voltage power line segments and low voltage data line segments. For example, the tap 320 may also include: positive and negative terminals for connection to a voltmeter, single conductor cable areas for attaching a current meter or clamp, an automobile high speed communication bus (CAN) for gathering/transmitting additional signal information to/from control processors, and auxiliary terminals for monitoring status command signals. The status/command signals may include: START/STOP, CHARGE OK and CONNECTION CHECK, and may be used to determine the charging level of the vehicle as well as detect faults in the transmission network.

Allowing all monitoring wires to be routed through the same insulated cable and docking connectors utilized for the EV power transmission provides the requisite safeguards, and obviates the need to open access panels to the charging cabinet or vehicle further, thereby reducing risk of electric shock to the operator. The close proximity of the lead outputs for use with monitoring devices, allows measurements to be taken from multiple devices or a single diagnostic tool. The charging cable segment 300 also increases the ease with which monitoring the status of the charger-vehicle system is performed, as the cable 300 may be readily attached, e.g., via latches, at opposite ends to the charging socket of the EV, and the docking attachment of the Fast Charge cable.

FIGS. 4 and 5 are perspective views illustrating one embodiment of first and second ends of the charging cable segment 300 having a docking mechanism and DC electric vehicle connector, respectively. The docking mechanism 400 illustrated in FIG. 4 may be a

CHAdeMO-compatible docking mechanism connectable to a complementary EVSE charging cable 105 (See FIG. 2). The DC electric vehicle connector 500 illustrated in FIG. 5 may be a CHAdeMO-compatible connector connectable to an EV. In alternative embodiments, the connectors are configured to enable docking with a any desired EVSE charging cable and EV, respectively.

FIG. 6 is an electrical schematic depicting an exemplary charging cable segment having test leads electrically coupled to the tap, with the tap coupled to a charging cable segment that is interposed between a first connector, e.g., a CHAdeMO TM or SAE 11772 compliant connector 600 and a second exemplary connector (AV50™) 605, where the second exemplary connector is configured to engage a CHAdeMO™ and/or SAE 11772 compliant connector of a charging cable of an EV charger. While the charging cable segment is depicted as having a tap composed of particular terminuses, the tap may be configured with other terminuses/connectors. The tapped lines depicted in FIG. 6 include high voltage test points 610, access for current measurement 615, the high and low wires for the high speed communication bus 620, and low voltage test points 625 for status/command signals such as: ground 630, charge permission 635, connection verification 640, charge start and stop_l 645, and charge start and stop_2 650. High value resistors 655, 660 may be in communication with the wires leading to the high voltage test points to provide a protection mechanism in the interest of safety. Thus, a high impedance meter may still accurately measure the voltage while the resistors may prevent a dangerous amount of current from flowing should a person come in contract with the high voltage rest points. Other means of safely isolating the high voltage test points may be utilized such as current limiters, voltage divides, or op amp circuitry.

FIG. 7 depicts one embodiment of the charging cable segment illustrated in FIG. 6 with test equipment coupled to an extension cable of the tap. The test equipment may include a voltage and current meter 700 to provide measurements without additional instruments that would otherwise need to be provided by the user, with the exemplary meter configuration 700 reducing the likelihood of a user mistakenly coming into contact with the high voltage test points 610. The voltage and current meter 700 may include digital readouts to display information representing the transmitted data, and recording equipment, and may feed their measurements into a wireless transmitter 705 integrated into the test assembly 710, or transmitted by wire to an external wireless communication device such as a smart phone, tablet or other handheld device. The other signal information available via the other test wires of cable embodiments may also be recorded or sent to a remote location via a wireless communication device 705.

FIG. 8 illustrates one embodiment of an EV charging cable that has an electrical tap in communication with a remote site through a detection unit. The EV charging cable 800 may be interposed between a first connector, e.g., a CHAdeMO TM or SAE 11772 compliant connector 805 and a second exemplary connector (AV50™) 810, where the second exemplary connector is configured to engage a CHAdeMO™ and/or SAE 11772 compliant connector 810 of a charging cable of an EV. The data line and power line segments may be monitored by test equipment such as a detection unit 815 through an extension cable 820 of a tap 825 and electrical measurements displayed on a local display 830 and/or transmitted to a user interface 835 located at a remote site 840. By providing the information to a remote site, a person skilled in the evaluation of the test signals may be available for evaluation of several similarly instrumented local sites and the personnel attaching the charging cable segment 800 to the charging system need no special skills beyond those normally used to hook up an EV charger.

In an additional embodiment of the invention, the extension assembly may be provided with means of modifying the signals found in the cable as they are passed back and forth between the charger and the EV. This type of embodiment may introduce additional risk into the situation as the unit becomes capable of overriding normal safety signals. This type of embodiment may require a much higher level of operator skill, but also may provide more powerful diagnostic tools.

FIG. 9 illustrates one embodiment of an EV simulator 900 having an external casing, power line test ports, data line test ports and a standard vehicle connector. A charger cable input port 905 may be configured to receive a SAE J 1772-compatible connector, CHAdeMO- compatible connector or other standards-based or de facto standard EV connector such as a DC Fast Charger connector. A 110 VAC input connector 910 or coupling may also be provided. A charging output connector 915 may be a SAE J 1772-compatible connector, CHAdeMO-compatible connector or other standards-based or de facto standard EV connector such as a DC Fast Charger connector. In one embodiment, a jumper cable 920 may be provided to short predetermined pins in the charging output connector 915 for test. RS-232 data line segment test ports 925 and post-type data line segment test ports 930 are provided through the external casing 935 to provide an electrical tap to an internal EV charger diagnostic extension cable (not shown).

FIG. 10 depicts one embodiment of an EV simulator that has an internal diagnostic extension cable coupled between a charger cable input port and a level-3 EV simulator 1000. A level-3 charger 1005 may be electrically coupled to the level-3 EV simulator 1000 through a charger cable input port 1010. A charging cable segment 1015 electrically couples the charger cable input port 1010 to the level-3 EV simulator 1000. A tap 1020 may be coupled to at least one of a power line segment and data line segment of the charging cable segment 1015. The tap 1020 may be provided with an extension cable 1025 to electrically couple the power line segment and data line segment to diagnostic output ports 1030 to monitor the data line and power segments for data. A switch 1035 is configured to selectively couple the level-3 EV simulator 1000 to one of a loop short 1040, a load simulator 1045 and a charging output connector 1050 for coupling to an EV (not shown).

FIG. 11 is a schematic illustrating another embodiment of an electrical tap provided for power and data segments at a location disposed between EVSE charger and EV data simulation board in an EV simulator. An EVSE charger such as a Fast Charger 1100 is coupled to an EV simulator 1105 through an EV charging cable 1110. An EV simulator connector element 1115 is configured to engage a CHAdeMO™ and/or SAE 11772 compliant connector 1120 of the EV charging cable 1110. Data and power line segments 1125, 1130 of the EV charging cable 1110 are further in communication with an EV data simulation board 1135 and an EV simulator high- voltage output connector 1140,

respectively. An electrical tap 1145 may be provided between the connector element 1115 and EV data simulation board 1135 and between the connector element 1115 and EV simulator high- voltage output 1140 to provide data and power line segment external test ports (1150, 1155), respectively. In one embodiment, the EV simulator high- voltage output connector 1140 may be a quick charger connector following a CHAdeMO protocol where the positive power supply line 1160 is jumped to the negative power supply line 1165 by jumper cable 1170 to simulate a connected EV and a closed EV contact. With the use of the jumper cable, the direct charger may invoke a test as whether a zero voltage charge is allowed without requiring the use of an actual EV and the test ports (1155, 1150) may be used to further evaluate the test results. The test may continue with the nominal command to charge the vehicle invoked by the DC charger 1100.

It may be contemplated that various combinations and/or sub-combinations of the specific features and aspects of the above embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments may be combined with or substituted for one another in order to form varying modes of the disclosed invention. Further it is intended that the scope of the present invention herein disclosed by way of examples should not be limited by the particular disclosed embodiments described above.

Claims

CLAIMS What is claimed is:

1. An electric vehicle ("EV") charging cable apparatus, comprising:

a charging cable segment having first and second ends, the charging cable segment having a power line segment and a data line segment;

a first element disposed at the first end of the charging cable segment, the first element configured to receive a direct current (DC) electric vehicle connector;

a DC electric vehicle connector disposed at the second end of the charging cable segment; and

a tap coupled to at least one of the power line segment and the data line segment wherein the at least one of the power line segment and the data line segment are tapped for external access.

2. The apparatus of claim 1 , wherein the tap comprises an extension cable electrically coupled to the power line segment and the data line segment.

3. The apparatus of claim 2, further comprising a test equipment coupled to the extension cable.

4. The apparatus of claim 2, further comprising a plurality of test leads electrically coupled to the power line segment and the data line segment through the extension cable.

5. The apparatus of claim 2, wherein said extension cable is sufficiently long to extend to at least to the first end and the second end to facilitate trouble-shooting.

6. The apparatus of claim 2, further comprising a transmitter coupled to the extension cable, said transmitter configured to transmit an electrical measurement of at least one of the power line segment and data line segment.

7. The apparatus of claim 6, further comprising a receiver for receiving said transmitted electrical measurement, said receiver coupled to a display.

8. The apparatus of claim 1, wherein the DC electric vehicle connector is an SAE J 1772- compliant connector.

9. The apparatus of claim 1, wherein the DC electric vehicle connector is a CHAdeMO- compliant connector.

10. The apparatus of claim 1, wherein the data line segment is a Controller Area Network (CAN) bus-compliant data line segment.

11. A method of monitoring communcations between an electric vehicle (EV) and an EV charging station, comprising:

providing power from an EV charging station to an EV through a power line segment of a charging cable segment;

sending data from an EV charging station to an EV through a data line segment of the charging cable segment; and

monitoring the data line segment for said data through a tap coupled to said data line segment.

12. The method of claim 11 , further comprising:

providing said data to an extension cable electrically coupled to the power line segment and the data line segment.

13. The method of claim 12, further comprising:

providing said data to test equipment through the extension cable.

14. The method of claim 12, further comprising:

providing said data to a plurality of test leads electrically coupled to the data line segment through the extension cable.

15. The method of claim 12, further comprising:

transmitting data associated electrical measurements of at least one of the power line segment and data line segment.

16. The method of claim 15, further comprising:

displaying information representing said transmitted data on a display.

17. The method of claim 11, further comprising:

monitoring the power line segment of the charging cable for power using the tap coupled to the power line segment.

18. The method of claim 17, further comprising:

providing data representative of the power in the power line segment to a display.

19. The method of claim 11, wherein the monitoring the data line segment for said data further comprises monitoring transmission rate.

20. The method of claim 11 , wherein the monitoring the data line segment for said data further comprises monitoring charging status.

21. An electric vehicle ("EV") charging apparatus, comprising:

an EV charger;

an EV electrically coupled to the EV charger through an EV charging cable, said EV charging cable having:

a power line segment; and

a data line segment;

an extension cable electrically coupled to at least one of the power line segment and the data line segment;and

a test equipment in communication with the at least one of the power line segment and the data line segment through the extension cable;

wherein a user may monitor real-time status of at least one of power through the power line segment and data through the data line segment to evaluate the status of the EV and EV charger, troubleshoot complications and monitor various parameters.

22. The apparatus of claim 21 , wherein the test equipment is in communication with the at least one of the power line segment and the data line segment through a wireless transmitter.

23. The apparatus of claim 21 , wherein the extension cable is sufficiently long to extend to at least both ends of the EV charging cable.

24. The apparatus of claim 21, wherein the EV charging cable is adapted to detachably connect to an SAE J1772-compliant connector.

25. The apparatus of claim 21 , wherein the EV charging cable is adapted to detachably connect to a CHAdeMO-compliant connector.

26. The apparatus of claim 21 , wherein the data line segment is a Controller Area

Network (CAN) bus-compliant data line segment.

28. An electric vehicle ("EV") charging cable apparatus, comprising:

means for receiving a direct current (DC) electric vehicle connector at the first end of the charging cable segment;

means for coupling to at least one of the power line segment and the data line segment wherein the at least one of the power line segment and the data line segment are tapped for external access.

29. The apparatus of claim 28, wherein the means for coupling comprises an extension cable electrically coupled to the power line segment and the data line segment.

30. The apparatus of claim 29, further comprising a test equipment coupled to the extension cable.

31. An electric vehicle ("EV") diagnostic cable apparatus, comprising:

a cable having a power line segment and a data segment;

a EVSE charger-compliant connector coupled to the power line segment and the data segment;

an EV simulator board coupled to the data line segment; and

an electrical tap in communication with the data line segment and disposed between the EV simulator board and the EVSE charger-compliant connector, the electrical tap in electrical communication with an external test port.

32. The apparatus of claim 31, further comprising:

a second electrical tap in communication with the power line segment and disposed between the EVSE charger-compliant connector and EV simulator high-voltage output connector, the electrical tap in electrical communication with a second external test port.