[0001] The present disclosure relates to an electric vehicle. More particularly, the present disclosure relates to a mode selector bi-directional In-Cable Control and Protection Device for charging and discharging of a plug-in hybrid or an electric vehicle.
BACKGROUND OF THE INVENTION
[0002] Conventional charging cable for alternating current (AC) charging of an electric vehicle comprises In-Cable Control and Protection Device (IC-CPD) that allows unidirectional power flow only, i.e., from alternating current (AC) mains to a plug-in hybrid or electric vehicle during charging. As shown in FIG. 1a, the AC main 101 is connected with an IC-CPD 103 via a harness 102 and a connector 105 is provided that is connected with the electric vehicle 106. The connector 105 is connected with the IC-CPD 103 via harness 104. As the IC-CPD 103 allows only unidirectional flow of alternating current (AC) from the AC mains 101 to the vehicle 106, the IC-CPD 103 controls the maximum allowed AC charging current to be supplied to the vehicle and performs all the required parameters check before and during the commencement of AC charging. Once the checks are completed and deemed to be OK by the IC-CPD 103, it closes the contactors present inside IC-CPD 103 and makes AC power available to the vehicle.
[0003] Technical Problem: In the existing charging cables, the IC-CPD 103 allows unidirectional power flow only, i.e., from AC mains to the vehicle. In case of a possible Vehicle to Load (V2L) and Vehicle to Vehicle (V2V) applications, i.e., supplying power from vehicle’s battery to an electrical load in house or any place, or to charge other vehicle’s battery, respectively. Therefore with existing charging cable, an entirely separate charging cable set to perform the desired power transfer while ensuring proper safety is required.
[0004] In some technologies, charging system is provided having a charging and discharging gun which comprises a shared module, a conversion module, a charging module and a discharging module. The shared module comprises a first charging and discharging gun head, a control box, and a connector female seat. The first charging and discharging gun head is connected to one end of the control box through a cable, and the other end of the control box is connected to the connector female seat. The conversion module includes a first male seat matched with the connector female seat and a second charging and discharging gun head connected to the first male seat. The charging module includes a second male seat matched with the connector female seat and a plug connected to the second male seat. The discharging module includes a third male seat matched with the connector female seat and a socket connected to the third female seat.
[0005] Technical problem associated with existing technology is that a special male and female pin connector is required to be developed. Further, the complete operation of the existing charging cable either in charging mode or in discharging mode is dependent on resistance value which further depend on the temperature therefore reliability is less. During the discharging mode, i.e., vehicle to vehicle application, there is no safety circuit in the charging cable, a safety circuit is to be provided in the car for safety. Therefore, the existing technology is just a juxtaposition of charging and discharging cable where the safety measures are done by the vehicle itself. Accordingly, the vehicle requires to have reverse charging safety features. When user connects the charging gun in vehicle, the controller of the vehicle will detect the PP (proximity pilot) resistor present in charging gun and accordingly the resistor value, it will send information to battery management system to select charge/discharge strategy accordingly. The charging and discharging is decided by the battery management system.
[0006] There is need in the art to develop a charging cable having IC-CPD which is able to perform both charging and discharging function with safety checks. Further, the charging cable should be independent of resistance and; final control and selection should be available with the user to perform the desired function. Further, control pilot generator circuit should be common and the control pilot circuit for charging and discharging modes should be able to operate independently. Further, a provision should be available to provide common low voltage power supply to the components inside IC-CPD in all modes of operation. Further, similar connectors can be used at both the sides of the IC-CPD for charging and discharging function simultaneously. In the above mentioned prior arts, all safety strategy matching is performed in the secondary vehicle and also all the safety strategy matching is resistance based which is not reliable.
SUMMARY OF THE INVENTION
[0007] This summary is provided to introduce concepts related to a bi-directional in-cable control and protection device for charging and discharging of plug-in hybrid or electric vehicle. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0008] The present disclosure provides a bi-directional in-cable control and protection device for charging and discharging of plug-in hybrid or an electric vehicle. The bi-directional in-cable control and protection device comprising a first end and a second end, the second end is configured to connect with primary vehicle and the first end (201) is configured to connect with a secondary vehicle or a load or AC voltage mains; relays are provided in between the first end and the second end to establish up a connection on voltage line (L, N, PE); a mode selector switch configurable to move in a first side position and a second side position to select charging and discharging mode; a low voltage power supply circuit configurable to connect with the voltage line (L, N) by means of the mode selector switch to convert AC voltage into low voltage DC to supply the low voltage DC to a controller and other IC-CPD loads such as relays, sensors, displays etc. The controller is coupled with the voltage sensors to receive first side voltage (V1), second side voltage (V2) and to perform voltage safety checks; current sensors to receive current and to perform current safety check; the mode selector switch to receive user’s mode selection input (D1) based on the first side position and the second side position; a sub-mode selector switch to receive user’s input for selecting discharging sub-mode; a control pilot circuit to provide control pilot signal on (CP1) or on (CP2), and a switch operated by the controller to complete the control pilot circuit by connecting either to the (CP1) circuit or (CP2) circuit; and a relay control circuit to control opening and closing of the relays. The controller controls the opening and closing of the relays based on inputs of mode selector switch, safety checks performed on the voltage (V1, V2), current and temperature and the communication on control pilot circuit (CP1 or CP2) in applicable modes of operation

[0009] In an aspect, during discharging mode when the plug-in hybrid or electric primary vehicle needs to be discharged to supply voltage to the load, the discharging mode is selected when: the mode selector switch is moved to the second position to connect the voltage line (L, N) coming from the second end of the IC-CPD to the low voltage power supply circuit, and the sub-mode selector switch is selected to the V2L discharging sub-mode; upon selecting the V2L discharging sub-mode, the controller closes the relays upon performing safety check on the voltage (V1, V2), the current, and temperature etc.
[0010] In an aspect, during discharging mode when the primary vehicle discharges to supply voltage to the secondary vehicle, the discharging mode is selected when: the mode selector switch is moved to the second position to connect the voltage line (L, N) coming from the second end of the IC-CPD to the low voltage power supply circuit, and the sub-mode selector switch is selected to the V2V discharging sub-mode; upon selecting the V2V discharging sub-mode, the controller closes the switch to complete the control pilot circuit by connecting the control pilot voltage (CP1) to R1 by means of the switch; and closes the relays upon performing safety check on the voltage (V1, V2), current and temperature, etc., and upon detection of required state of CP signal to initiate charging.
[0011] In an aspect, during charging mode, the mode selector switch in the first side position connects the voltage line (L,N) coming from the first end of IC-CPD to the low voltage DC power supply circuit, when the charging mode is selected, the controller closes the switch to complete the control pilot circuit by connecting the control pilot (CP2) circuit with the resistor R1; and closes the relays upon performing safety checks on the voltage (V1, V2), current and temperature etc. and upon detection of required state of CP signal to initiate charging. In an aspect, the mode selector switch is a triple pole double throw (TPDT) switch.
[0012] In an aspect, the sub-mode selector switch is a push button or a toggle switch or a touch based input on IC-CPD’s display.
[0013] In an aspect, the controller performs safety checks on voltage by detecting over voltage and under voltage, current by detecting over current leakage, temperature by detecting over temperature and under temperature, the controller closes relays when safety checks are under safe conditions.
[0014] In an aspect, the controller does not close the relay when both, the first side voltage (V1) and the second side voltage (V2) are greater than zero.
[0015] In another embodiment of the present subject matter a method performed by bi-directional In-Cable Control and Protection Device for charging and discharging of plug-in hybrid or an electric primary vehicle. The method comprises selecting charging mode and discharging mode based on inputs of a mode selector switch; receiving, a controller, a low voltage from a low voltage power supply circuit; performing, by the controller safety checks related to voltage, current, and temperature on the bi-directional In-Cable Control and Protection Device; determining, by the controller, charging mode and discharging mode, the determining further comprises determining charging mode when first side voltage (V1) is greater than ‘0’ and second side voltage (V2) is equal to ‘0’ and mode selection input (D1) is equal to ‘1’; and determining discharging mode when the first side voltage (V1) is equal to ‘0’ and the second side voltage (V2) is greater than ‘0’ and the mode selection input (D1) is equal to ‘0’.
[0016] In an aspect, the determining further comprises determining, based on input from a sub-mode selector switch, V2L discharging mode is selected; and determining, based on input from a sub-mode selector switch, V2V discharging mode is selected.
[0017] In an aspect, the method further comprises charging, upon closing relay and completing control pilot voltage (CP1 or CP2) circuit, the primary vehicle and the secondary vehicle; and supplying, upon closing the relay, voltage to load.
[0018] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0019] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF FIGURES
[0020] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0021] FIG. 1a, 1b, and 1c illustrate components of a connected in-cable control and protection device with primary vehicle with mains in the charging mode, and primary vehicle with load or secondary vehicle in discharging mode respectively, in accordance with an embodiment of the present subject matter;
[0022] FIG. 2 illustrates architecture of in-cable control and protection device (IC-CPD), in accordance with an embodiment of the present subject matter;
[0023] FIG. 3 illustrates architecture and circuit block diagram of the IC-CPD when normal charging mode is selected;
[0024] FIG. 4 illustrates architecture and circuit block diagram of the IC-CPD when discharging mode is selected for discharging of primary vehicle to load;
[0025] FIG. 5 illustrates architecture and circuit block diagram of the IC-CPD when discharging mode is selected for discharging of primary vehicle to secondary vehicle;
[0026] FIG. 6a, 6b, 6c, and 6d (combinedly FIG. 6) illustrate a method of working of the IC-CPD, in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0027] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0028] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0029] The terminology used herein is to describe particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0030] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0031] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0032] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
[0033] Hereinafter, a description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present disclosure.
[0034] Control Pilot Circuit: Communication line used to signal charging level (through pulse width modulation signal generated by EVSE or IC-CPD between the vehicle and the EVSE or IC-CPD, can be manipulated by vehicle to initiate charging as well as exchange any other information.
[0035] Safety Error: Any error which causes deviation from normal functioning and might compromise safety of the system may be termed as safety error. Below are possible safety errors:
[0036] RCD Error: RCD refers to residual current detection. RCD error occurs when the difference between current in supply (live) and return (neutral) conductors is more than a threshold limit. It indicates leakage of current and presents a shock hazard.
[0037] Voltage Error: Voltage error can be over voltage or under voltage error. If the voltage measured by sensor is above the threshold value it is consider as over voltage condition. If the voltage measured by sensor is below a threshold value, it is considered as low voltage condition.
[0038] Over Current Error: When current measured by sensor is above the threshold current value it can be considered as over current condition.
[0039] FIG. 1 illustrates components of charging cable with in-cable control and protection device (IC-CPD). A charging cable for AC charging of a plug-in hybrid or an electric vehicle consists mainly of three parts in-cable control and protection device 103, a pair of Harness – first harness 102, 111, 112 and a second harness 104. The pair of harness 102, 111, 112, 104 have their respective connectors at both ends to connect with AC mains 101, load 107, and secondary vehicle 108, and primary vehicle 106. For example, the harness 102 has a connector at one end to connect with the AC mains 101. The harness 111 has a connector at one end to connect with the load 107. The harness 112 has a connector 109 to connect with the secondary vehicle 108. The harness is integrated with the connectors at first end (201) which is replaced by the user for the required function, for example, when vehicle to load condition is required corresponding harness 111 with the connector is connected with the IC-CPD 103. In all cases, one end of the harness 102, 111, 112 is connected with the IC-CPD 103. In an embodiment, the harness 104 at the primary vehicle side can be integrated with the IC-CPD 103. In another embodiment, both the harnesses and the IC-CPD 103 are detachable from each other and attachable to each other.
[0040] The IC-CPD 103 as the name suggests, controls the maximum allowed AC charging current to be supplied to the vehicle and performs all the required parameters check before and during the commencement of AC charging. Once the checks are completed and determined to be safe by the IC-CPD 103, the IC-CPD 103 makes connection and supplies AC power to the primary vehicle during charging.
[0041] As indicated by the arrow 110 in FIG. 1a, 1b, and 1c in combination with FIG. 3, 4, and 5 respectively, primary vehicle 106 receives power from AC mains 101 during charging mode. Also primary vehicle 106 provides power to a load 107, and primary vehicle 106 provides power to the secondary vehicle 108 during discharging mode via respective harnesses having their corresponding connectors.
[0042] The present disclosure also provides a bi-directional IC-CPD 103 with a mode selector switch on it to support power flow in both directions, i.e., from AC mains to primary vehicle in case of vehicle charging, and from vehicle to electrical load or to secondary vehicle in case of primary vehicle to the load (V2L) charging or primary vehicle to secondary vehicle (V2V) charging, respectively.
[0043] The present IC-CPD 103 disclosed in the present disclosure eradicates the need of an entirely separate charging cable set for V2L/V2V applications and allows bi-directional power function with a single IC-CPD 103. With the present IC-CPD 103, only harness at first end (201) is to be replaced with the required harness as per desired operation.
[0044] FIG. 2 illustrates architecture and circuit diagram of IC-CPD 200 (103 of FIG. 1a, 1b, and 1c) in unconnected state. The IC-CPD 200 comprises a first end 201 and a second end 202, where the second end 202 is configured to connect with primary vehicle 301 and the first end 201 is configured to connect with AC mains 304, or a secondary vehicle 303 or a load 302 in different conditions as desired. The voltage line L, N, PE comprises positive line (L), neutral line (N) and a potential earth (PE). Control pilot circuit or line (CP) is provided to signal charging level between the car and the electric vehicle supply equipment (EVSE) or IC-CPD, can be manipulated by vehicle to initiate charging as well as other information.
[0045] As shown in FIG. 2, a set of relays 204 is provided in between the first end 201 and the second end 202 to establish a connection on voltage line L, N, PE. The relays 204 are controlled by a relay control circuit 210 which is further controlled by a controller 203. The IC-CPD 200 further comprises a mode selector switch 206 that is configurable to move in a first side position 206a and a second side position 206b to select charging and discharging mode, respectively. The mode selector switch 206 may be triple pole, double throw (TPDT) or any known switch which can work on triple pole to make connections.
[0046] As shown in FIG. 2, a low voltage power supply circuit 207 is provided to convert the AC voltage into low voltage DC from the voltage line (L, N, PE) either coming from AC mains or coming from the primary vehicle. The low voltage power supply circuit 207 supplies the low voltage DC to the controller 203 and other IC-CPD’s internal low voltage components such as relays, sensors, display, to perform all safety checks and control closing and opening of the relays 204 and for operation of the other internal low voltage components. The low voltage power supply circuit 207 configurable to connect with the voltage line (L, N) by means of the mode selector switch 206 to convert the AC voltage into low voltage DC to supply the low voltage DC to the controller 203 and other IC-CPD’s internal low voltage components such as relays, sensors, display, etc.
[0047] As Shown in FIG. 2, the controller 203 is coupled with the voltage line (L, N, PE) through voltage measurement sensors to receive first side voltage ‘V1’ and second side voltage ‘V2’ coming from the primary vehicle 301. The controller 203 compares the first voltage ‘V1’ with a predefined upper threshold limit and lower threshold limit of the first voltage ‘V1’. Similarly, the controller 203 compares the second voltage ‘V2’ with a predefined upper threshold limit and lower threshold limit of the second voltage ‘V2’. If the first voltage ‘V1’ and the second voltage ‘V2’ are not within the predefined upper and lower threshold limit, the controller 203 raises an error and does not start charging or discharging function of the primary vehicle.
[0048] Similarly, the controller 203 receives current measured through current sensors and compares the current with predefined upper threshold limit and makes decision to open the relay 204. The controller 203 also detects any current leakage in the system. The controller 203 receives temperature inputs from installed temperature sensor 211 to determine safe working condition of the IC-CPD 200. Working of the safety checks are not disclosed in detail as these are well known to a person skilled in the art.
[0049] As shown in FIG. 2, the mode selector switch 206 is also coupled with the controller 203 to provide mode selection input ‘D1’ based on the first side position 206a and the second side position 206b. As the mode selection input ‘D1’ is coupled to a pin of the controller 203 to provide value of ‘0’ or ‘1’. A sub-mode selector switch 208 is provided which is coupled with the controller 203 to provide sub-mode selection input for selecting discharging mode 400, 500. A control pilot circuit having two branches CP1, CP2 which can be considered as first side control pilot circuit CP1 and second side control pilot circuit CP2. Both the first side control pilot circuit CP1 and second side control pilot circuit CP2 are coupled with the controller 203 and the controller 203 completes the circuit by joining the first side control pilot circuit CP1 or second side control pilot circuit CP2 with a controller as per the selected mode by means of a CP selector switch 209 which is operated by the controller 203. The controller 203 generates the control pilot circuit signal for CP1 or CP2 for safe charging and/or discharging of primary vehicle.
[0050] The controller 203 controls the opening and the closing of the relays 204 based on the inputs of the mode selector switch 206, result of the safety checks performed, and the communication on control pilot circuit (CP1 or CP2) between IC-CPD 200 and the primary or secondary vehicle. When the results of the safety checks are not in predefined limit, the controller 203 does not close the relays 204 to establish connection between the first end 201 and the second end 202. The controller 203 closes the relays 204 correspond to PE and CP circuit together in case of charging mode and V2V discharging sub-mode. Further, the controller 203 closes the relays 204 corresponding to L, N, and PE at different timings.
[0051] As explained above, the safety checks include voltage detection and monitoring, current monitoring, leakage current monitoring, relay contact status, ground monitoring, and temperature check by PCB temperature sensor, etc. These safety checks are performed using sensors, also corrective actions are taken by the controller 203, if needed. When the results of these checks are found to be ok or in working range, only then the controller 203 closes the relays 204 for charging or discharging. Safety checks are also performed during charging or discharging and the controller 203 takes action and opens relays 204, if any fault/error is found in the system.
[0052] FIG 3 illustrates architecture and circuit block diagram when charging mode 300 is selected by changing the position of the mode selector switch 206 to the first side position 206a, the controller 203 receives mode selection input ‘D1’ on pin as value ‘1’. The low voltage power supply circuit 207 receives power from the voltage line (L, N, PE) and converts the same to low voltage DC and supplies the low voltage DC to the controller 203 and other IC-CPD’s internal low voltage components, such as relays, sensors, display, etc.
[0053] Upon receiving the power or low voltage DC supply, the controller 203 simultaneously performs various checks on voltage V1, V2, input current, and temperature. When the first side voltage ‘V1’ is more than ‘0’ and second side voltage ‘V2’ is equal to ‘0’ and value at mode selection input ‘D1’ is equal to ‘1’, the controller 203 identifies the selection as charging mode 300. Upon selection of charging mode 300, the controller 203 closes the switch 209 to complete the control pilot circuit by connecting the control pilot (CP2) circuit with the resistance (R1) which is connected with the controller 203 and closes the relays 204 upon performing safety checks on the voltage (V1, V2), current and temperature and as per the communication on CP circuit line between the controller and the primary vehicle. Upon activation of the control pilot circuit CP2, and closing of the relay 204, the voltage line (L, N, PE) supplies AC voltage to the primary vehicle 301 for charging of the primary vehicle.
[0054] The plug-in hybrid or electric vehicle has an on-board charger (OBC) and an inverter for charging and discharging a traction battery pack. For bi-directional IC-CPD’s discharging modes V2V500, V2L 400 to work, at least the primary plug-in hybrid or electric vehicle must have a bi-directional OBC or an inverter or any other device which can convert traction battery pack’s stored DC power to AC power, along with a discharging mode button, provided in the vehicle console, selected by the user to perform the discharging function of the primary plug-in hybrid or electric vehicle. The user may give discharge command to the primary plug-in hybrid or electric vehicle by means of connected hand-held computing device, such as mobile phone, key fob etc.
[0055] FIG 4, illustrates an architecture and a circuit diagram of the IC-CPD 200 for selecting discharging mode 400 by changing the position of the mode selector switch 206 to a second side position 206b. When the mode selector switch 206 is moved towards the second side position 206b, the mode selection input value ‘D1’ is changed to value ‘0’ as it is connected to negative pin. In the discharging mode 400 the plug-in hybrid or electric primary vehicle is discharged to supply voltage to the load 302. The discharging mode 400 is selected when the mode selector switch 206 is moved to the second side position 206b to connect the voltage line (L, N) coming from the second end of the primary vehicle to the low voltage power supply circuit 207. The low voltage power supply circuit 207 converts the AC voltage into low voltage DC and supplies the same to the controller 203 for its functioning and operations. When the first side voltage ‘V1’ is equal to voltage ‘0’ and the second side voltage ‘V2’ is more than voltage ‘0’ and mode selection input value ‘D1’ is equal to ‘0’, the controller 203 selects the discharging mode 400, 500. The controller 203 further checks sub-mode selection input value ‘D2’ of the sub-mode selector switch 208. The sub-mode selection input value ‘D2’ is for discharging mode 400 or 500, for example, primary vehicle to load 302 power transfer, or primary vehicle to secondary vehicle power transfer. The sub-mode selection input value ‘D2’ may also be in binary form like ‘1’ or ‘0’ or positive or negative. The binary value ‘1’ of D2 may be for discharging mode 400 for the vehicle to the load (V2L) and the binary value ‘0’ of D2 may be for discharging mode 500 which is the vehicle to the vehicle (V2V) discharging mode or vice-versa. Upon selecting the discharging mode 400, the controller 203 closes the relays 204 upon performing safety checks on the voltage (V1, V2), the current, and temperature. In the present V2L or discharging mode 400, the control pilot circuit (CP1, CP2) remains open.
[0056] FIG 5 illustrates a circuit diagram of discharging mode 500 which is a V2V (vehicle to vehicle) discharging sub-mode, where one vehicle is discharging and other vehicle is charging, more specifically primary vehicle is discharging and secondary vehicle is charging. When the first side voltage ‘V1’ is equal to zero and the second side voltage ‘V2’ is more than zero and the mode selection input value D1 is equal to binary value ‘0’, the controller 203 selects the discharging mode 400, 500. The discharging mode 500 is determined when the sub-mode selector switch 208 is selected to the discharging mode 500. Upon selecting the discharging mode 500, the controller 203 closes the switch 209 to complete the control pilot circuit by connecting the control pilot (CP1) circuit with the resistance (R1) by means of the CP selector switch (209) and closes the relays 204 upon performing safety checks on the voltage (V1, V2), current and temperature and as per the communication on CP circuit line between the controller and the secondary vehicle. Once the connection on the voltage line is established, the primary vehicle is discharged by providing AC voltage to the voltage line (L, N, PE) which goes to the secondary vehicle by charging cable and the IC-CPD 200.
[0057] Even during the charging mode 300 or discharging mode 500, if there is any communication fault that occurs via the control pilot circuit (CP1, CP2), the controller 203 acts in safe mode and opens the relay 204 and displays the corresponding error. In another situation where the D1 state is changed by the user, i.e., by changing the position of mode selector switch 206 by the user after commencement of charging or discharging, the controller acts in emergency mode. The controller 203 opens the relay 204 and disconnects the charging or discharging mode and display the error on the display screen that may be provided on the IC-CPD 200. Hence, the mode selector switch 206 can also act as an emergency switch for the user to manually command the controller 203 to stop power flow during any external hazardous events. During use of the IC-CPD 200, if there is any error like, EV ready error, communication fault, charging error, safety error, or D1 state change, the controller 203 automatically opens the relay 204 and stops the power transfer through the IC-CPD 200.
[0058] FIG. 6A-6D (combined Fig. 6) illustrates a method 600 of operating the IC-CPD 200 in accordance with an embodiment of the present disclosure and functioning of FIG. 3, 4, and 5. The order in which the method is described is not intended to be construed as a limitation, and any number of the described blocks can be combined in any appropriate order to carry out the method or an alternative method. Additionally, individual blocks may be deleted from the flowchart without departing from the scope of the subject matter described herein. The present figure is divided into four parts as the method includes all steps for charging mode 300, discharging mode 400, and discharging mode 500. The four parts is to be construed as a single figure.
[0059] In FIG. 6A, the method 600 includes selecting 601, by the mode selector switch 206, charging mode 300 and discharging mode 400 or discharging mode 500.
[0060] At step 602, the method includes changing the first harness 102, 111, 112 as per the selected mode at step 601. For example, if charging mode 300 is selected, the harness 102 is connected with the IC-CPD 200. If discharging mode 400 is selected, the harness 111 is connected with the IC-CPD 200. If discharging mode 500 is selected, the harness 112 is connected with the IC-CPD 200. In the present charging cable, only first harness 102, 111, 112 having desired connector is replaced at the first end 201 of the IC-CPD 200.
[0061] At step 603, the method includes connecting the connector which will provide AC power source according to the selected mode, i.e., connecting the first side harness to the AC main for charging mode. Or, connecting the second side harness to the primary vehicle for discharging mode. The user enables the discharging mode in the primary vehicle by selecting button on vehicle console or by means of connected hand-held computing device, such as mobile phone, etc.
[0062] At step 604, the method includes powering up the controller 203 of the IC-CPD 200 by the low voltage supply circuit 207 during charging 300 and discharging mode 400, 500. When there is no power supply to the controller 203, checking the selected mode and connections at step 605.
[0063] At step 606, the method includes performing checks, i.e., confirming that all sensors and functions blocks of IC-CPD 200 are working correctly, checking voltage at first side and second side and mode selection input value ‘D1’ by the controller 203 upon receiving the low voltage power supply.
[0064] At step 607, the method includes checking whether safety check is OK. When safety check at step 607 is not OK, the controller 203 sets fault and displays the error at step 608. When safety check at step 607 is OK or in working range, the controller 203 further determines the selected mode.
[0065] At step 609, the method includes determining whether the first side voltage ‘V1’ is greater than voltage value ‘0’, the second side voltage ‘V2’ is equal to value ‘0’ and the mode selection input value ‘D1’ is equal to binary number ‘1’, i.e., V1>0, V2==0, and D1=1, the controller 203 determines that charging mode 300 is selected at step 613.
[0066] At step 613a, the method includes determining whether the first side voltage ‘V1’ is within the operation range that is within upper threshold limit and lower threshold limit. When the first side voltage ‘V1’ does not fall under operation range, the controller 203 sets fault or raise error and display the same at step 613b.
[0067] At step 610, when V1==0, V2>0, and D1==0, the controller 203 determines that discharging mode 400 or discharging mode 500 is selected at step 614 in the method.
[0068] At step 611, when V1>0 and V2>0, or when V1==0 and V2==0, the controller 203 determines that there is a fault or an error in the IC-CPD 200 at step 612. The controller 203 may display the error to user on the display screen of the IC-CPD 200.
[0069] At step 615, the method includes selecting discharging sub-mode operation by the sub-mode selector switch 208. The sub-mode selector switch 208 may be a push button switch which indicates two binary value ‘1’ or ‘0’ where binary value ‘1’ may be associated with selection of discharging mode 400 which is V2L and binary value ‘0’ may be associated with selection of discharging mode 500 which is V2V or vice versa. Based on the sub-mode selection input value ‘D2’, the controller 203 determines whether the discharging mode 500 is selected at step 616 or the discharging mode 400 is selected at step 617.
[0070] At step 618, the method includes determining whether the second side voltage ‘V2’ is within the operation range that is within upper threshold limit and lower threshold limit. When the second side voltage ‘V2’ does not fall under operation range, the controller 203 sets fault or raise error and display the same at step 619.
[0071] At step 622, the method includes connecting the control pilot (CP1) circuit with the resistance (R1) which is connected with controller 203 by the switch 209 and closing the PE relay of 204 by the controller 203 along with activation of CP circuit.
[0072] At step 624, the method includes displaying that IC-CPD 200 is ready for discharging the primary vehicle 301. The harness 112 with connector 109 is connected to the secondary vehicle.
[0073] At step 626, the method includes connecting the control pilot (CP2) circuit with the resistance (R1) by the switch 209 and closing the PE relay of 204 by the controller 203.
[0074] At step 627, the method includes connecting the connector 105 to the primary vehicle 106 by the user for charging the primary vehicle.
[0075] At step 628, the method includes checking safety functions, communication functions, L and N relay control timings as per charging standard for both charging mode 300 where primary vehicle is being charged and discharging mode 500 where the secondary vehicle is being charged.
[0076] At step 629, the method includes performing continuous test on the charging system parameters. To check if there is any communication fault or electric vehicle ready error or charging error or any safety related error (such as voltage fault, over current fault, RCD fault, temperature related fault, etc.) or D1 state change by the controller 203.
[0077] At step 630, the method includes changing the CP circuit state/parameters according to charging standard, opening the L and N relay 204, and set fault and stop charging when there is any occurrence of error or state change in D1. The controller 203 stops charging the primary vehicle or secondary vehicle as per the connections.
[0078] At step 620, the method includes determining whether second side voltage ‘V2’ is within the operation range or not. If the second side voltage is not within the operation range, the controller 203 sets fault at step 621.
[0079] At step 623, the method includes closing the PE, L and N relay of relays 204 by the controller 203 when the second side voltage ‘V2’ is within the operation range.
[0080] At step 625, the method includes displaying that the IC-CPD 200 is ready for discharging mode 400. The method further indicates connecting the AC loads to be powered to sockets available at the connector at the first end 201 of the IC-CPD 200.
[0081] At step 631, the method includes performing continuous test on the charging system. If there is any RCD error, voltage error, over current error, temperature error, or change of D1 state detected, the controller 203 opens the relay 204 and sets fault or error on the system and displays to user on IC-CPD display.
[0082] Thus, the In-Cable Control and Protection Device of the present disclosure uses a common power conversion module (AC to LV DC) for all the modes. Mode selection switch may also be used as emergency switch to cut power supply by opening of line relays. No any other special connectors or multiple connectors are required for implementing this IC-CPD. It eliminates the need of providing a control pilot generator circuit in primary EV for V2V charging, thus it saves cost and makes V2V charging economical.
[0083] The foregoing description of the preferred embodiment of the invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive, nor is it intended to limit the invention to the precise form disclosed. It will be apparent to those skilled in the art that the disclosed embodiment may be modified in light of the above teachings.

Claims:We claim:
1. A bi-directional In-Cable Control and Protection Device (200) for charging and discharging of an electric primary vehicle (301), the bi-directional In-Cable Control and Protection Device (200) comprising:
a first end (201) and a second end (202), the second end (202) is configured to connect with primary vehicle (301) and the first end (201) is configured to connect with an AC mains (304), a secondary vehicle (303) or a load (302);
relays (204) provided in between the first end (201) and the second end (202) to establish a connection on voltage line (L, N, PE);
a mode selector switch (206) configurable to move in a first side position (206a) and a second side position (206b) to select charging and discharging mode;
a low voltage power supply circuit (207) configurable to connect with the voltage line (L, N) by means of the mode selector switch (206) to convert AC voltage into low voltage DC to supply the low voltage DC to a controller (203);
the controller (203) coupled with:
voltage sensors on the voltage line (L, N, PE) to receive first side voltage (V1), second side voltage (V2) and to perform voltage safety check;
current detection circuit (205) to receive current and to perform current safety check;
the mode selector switch (206) to receive mode selection input (D1) based on the first side position (206a) and the second side position (206b);
a sub-mode selector switch (208) to receive input for selected discharging sub-mode (400, 500);
a control pilot circuit to provide control pilot signal CP1 or CP2, and a switch (209) operated by the controller (203) to complete the control pilot voltage circuit (CP1, CP2) by connecting either control pilot 1 (CP1) circuit or control pilot 2 (CP2) circuit with resistance (R1) of the controller (203); and
a relay control circuit (210) to control opening and closing of the relay (204);
the controller (203) controls the opening and the closing of the relays (204) based on inputs of the mode selector switch (206), the safety checks performed on the voltage (V1, V2), current and temperature, and as per communication on the control pilot circuit (CP1 or CP2) for applicable modes (300, 500).

2. The bi-directional In-Cable Control and Protection Device (200) as claimed in claim 1, the mode selector switch (206) is moved to the second position (206b) to connect the voltage line (L, N) coming from the second end (202) of the IC-CPD (200) to the low voltage power supply circuit (207), and
the sub-mode selector switch (208) is selected to enable the discharging mode (400);
upon selecting the discharging mode (400), the controller (203) closes the relays (204) upon performing safety checks on voltage, current, and temperature.

3. The bi-directional In-Cable Control and Protection Device (200) as claimed in claim 1, the mode selector switch (206) is moved to the second position (206b) to connect the voltage line (L, N) coming from the second end (202) of the IC-CPD (200) to the low voltage power supply circuit (207), and
the sub-mode selector switch (208) is selected to the discharging mode (500);
upon selecting the discharging mode (500), the controller (203):
closes the switch (209) to complete the control pilot voltage circuit CP1 by connecting the control pilot 1 (CP1) circuit with the resistance (R1) by means of the switch (209); and
closes the relays (204) upon performing safety check on the voltage (V1, V2), current and temperature and as per the communication on the control pilot circuit (CP1).
4. The bi-directional In-Cable Control and Protection Device (200) as claimed in claim 1, wherein during charging mode (300), the mode selector switch (206) is in the first side position (206a) connects the voltage line (L,N) coming from the first end (201) of the IC-CPD to the low voltage power supply circuit (207),
when the charging mode (300) is selected, the controller (206):
closes the switch (209) to complete the control pilot circuit by connecting the control pilot 2 (CP2) circuit with the resistance (R1); and
closes the relays (204) upon performing safety checks on the voltage, current and temperature and as per the communication on the control pilot circuit 2 (CP2).

5. The bi-directional In-Cable Control and Protection Device (200) as claimed in claim 1, wherein the mode selector switch (206) is a triple pole double throw (TPDT) switch.
6. The bi-directional In-Cable Control and Protection Device as claimed in claim 1, wherein the sub-mode selector switch (208) is a push button, a toggle switch or a touch based option on IC-CPD display.
7. The bi-directional In-Cable Control and Protection Device (200) as claimed in claim 1, wherein the controller (203) performs safety checks on voltage by detecting over voltage and under voltage, on current by detecting over current and under current, on temperature by detecting over temperature and under temperature and on PE connection detection, further the controller (203) closes relay (204) when safety checks are under safe conditions.
8. The bi-directional In-Cable Control and Protection Device (200) as claimed in claim 1, wherein the controller (203) does not close the relay (204) when both, the first side voltage (V1) and the second side voltage (V2) are greater than zero.
9. The bi-directional In-Cable Control and Protection Device (200) as claimed in claim 1, wherein the controller (203) opens the relays (204) when state of the mode selection input (D1) is changed and disconnects the charging or discharging mode and displays the error on the display screen.
10. A method (600) performed by bi-directional In-Cable Control and Protection Device (200) for charging and discharging of an electric vehicle, the method (600) comprising:
selecting (601) charging mode (300) and discharging mode (400, 500) based on inputs of a mode selector switch (206);
receiving (604), by a controller (203), a low voltage from a low voltage power supply circuit (207);
performing (606), by the controller (203) safety checks related to voltage, current, and temperature on the bi-directional In-Cable Control and Protection Device (200);
determining (609, 610), by the controller (203), charging mode (300) and discharging mode (400, 500), the determining (609, 610) comprises:
determining (609) charging mode (300) when first side voltage (V1) is greater than ‘0’ and second side voltage (V2) is equal to ‘0’ and mode selection input (D1) is equal to ‘1’; and
determining (610) discharging mode (400,500) when the first side voltage (V1) is equal to ‘0’, the second side voltage (V2) is greater than ‘0’ and the mode selection input (D1) is equal to ‘0’.

11. The method (600) as claimed in claim 10, wherein the determining (610) further comprises:
determining (616), based on input from a sub-mode selector switch (209), discharging mode (500) is selected; and
determining (617), based on input from a sub-mode selector switch (209), discharging mode (400) is selected.

12. The method (600) as claimed in claim 10, wherein the method (600) further comprises:
charging (628), upon closing relay (204) and completing control pilot (CP1, CP2) circuit, the primary vehicle (301) and the secondary vehicle (303); and
supplying (625), upon closing the relay (204), power to load (302).