DESC:CONNECTOR FOR CHARGING ELECTRIC VEHICLE(S)
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202321031052 filed on 01/05/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to an electric power-supplying apparatus of electric vehicle(s). The present disclosure particularly relates to a connector for charging electric vehicle(s).
BACKGROUND
Recently, there has been a rapid development in electric vehicles because of their ability to resolve pollution-related problems and serve as a clean mode of transportation. Generally, electric vehicles include a battery pack, power pack, and/or combination of electric cells for storing electricity required for the propulsion of the vehicles. The electrical power stored in the battery pack of the electric vehicle is supplied to the traction motor for moving the electric vehicle. Once the electrical power stored in the battery pack of the electric vehicle is depleted, the battery pack is required to be charged from a power source.
Electric vehicle charging is functionally similar to charging of any other electronic/electric device. However, the electric vehicle battery pack stores a large amount of power, and hence, requires a longer charging duration. To solve the problem of longer charging time, charging systems have been developed that are capable of delivering large amounts of power to the battery pack, hence, reducing the charging time required to charge the battery pack of the electric vehicle. The electric vehicle charging systems comprise a power supply, a charging cable, and a charging connector. Since the electric vehicle charging systems supply large amounts of power in the vicinity of the human user of the vehicle, it is important for the charging connectors to have protection devices.
The existing charging gun(s) and connectors include either an inline protection device or a protection device located at the grid end, which makes the charging connector bulky and inconvenient to carry. Especially, it is very difficult to carry the bulky connector in the limited space available in electric two-wheel vehicles.
Moreover, the existing inline and/or grid-end protection devices are unable to provide earth presence detection and protection. Such a lack of earth sensing and protection may harm the user of the vehicle in cases when there is a large leakage current.
Therefore, there exists a need for an improved charging connector that overcomes one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a charging connector for an electric vehicle.
Another object of the present disclosure is to provide a charging connector for an electric vehicle with earth sensing and protection.
In accordance with an aspect of the present disclosure, there is provided an electric vehicle charging connector. The connector comprises a supply line, a leakage current sensing module, an earth sensing module, and a supply control module. The supply line is configured to electrically connect a power source to a load. The leakage current sensing module is configured to detect a leakage current from the supply line. The earth sensing module is configured to detect presence of an earth line of the power source. The supply control module is coupled with the supply line, the leakage current sensing module, and the earth sensing module. The supply control module is configured to disconnect the power source from the load when the earth sensing module fails to detect presence of the earth line of the power source.
The present disclosure discloses the electric vehicle charging connector. The charging connector as disclosed by the present disclosure is capable of fast charging the electric vehicle. The charging connector as disclosed by the present disclosure is advantageous in terms of detecting the presence of the earth line of the power supply. Beneficially, the charging connector as disclosed by the present disclosure is advantageous in terms of displaying the status of the earth line. Beneficially, the charging connector as disclosed by the present disclosure is advantageous in terms of not allowing the flow of power from the power source to the load (battery pack of the vehicle) for the proactive safety of the vehicle user. Beneficially, the charging connector as disclosed by the present disclosure is advantageous in terms of eliminating any risk of electrocution of the vehicle user while charging the battery pack of the electric vehicle.
Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
Figure 1 illustrates a block diagram of an electric vehicle charging connector, in accordance with an aspect of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of an electric vehicle charging connector and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, or system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings 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.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well-known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the terms “electric vehicle”, “EV”, and “EVs” are used interchangeably and refer to any vehicle having stored electrical energy, including the vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries that are exclusively charged from an external power source, as well as hybrid vehicles which may include batteries capable of being at least partially recharged via an external power source. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheelers, electric three-wheelers, electric four-wheelers, electric pickup trucks, electric trucks, and so forth.
As used herein, the terms “battery pack”, “battery”, and “power pack” are used interchangeably and refer to multiple individual battery cells connected to provide a higher combined voltage or capacity than what a single battery can offer along with the necessary electronic components and circuitry required to do so. The battery pack is designed to store electrical energy and supply it as needed to various devices or systems. Battery packs, as referred herein may be used for various purposes such as power electric vehicles and other energy storage applications. Furthermore, the battery pack may include additional circuitry, such as a battery management system (BMS), to ensure the safe and efficient charging and discharging of the battery cells. The battery pack comprises a plurality of cell arrays which in turn comprises a plurality of battery cells.
As used herein, the term “connector” refers to a specialized plug that connects an electric vehicle to a charging station or outlet, allowing the battery to be recharged. The connector may comprise a standardized connector or a proprietary connector.
As used herein, the term “supply line” refers to wires that carry the electrical current from the power source (like an outlet or charging station) to the device being charged. The supply line may comprise a conductor and an insulation material.
As used herein, the term “leakage current module” refers to an electronic device capable of detecting any leakage current in the electric vehicle and/or load. The leakage current sensing module is configured to detect and measure unwanted electrical current flow in a circuit.
As used herein, the term “earth sensing module” refers to an electronic device capable of detecting and monitoring the quality of a ground connection in an electrical system.
As used herein, the term “supply control module” refers to an electronic device present in the connector capable of controlling the flow of electric power through the connector. The supply control module may act as a switch inside the connector, which in open condition, would disrupt the flow of electric power from the power source to the load via the supply line.
As used herein, the term “load” refers to the battery pack of the electric vehicle which is being charged by the charging connector from the electric power received from the power source.
As used herein, the term “connector live line” refers to a wire or cable (conductor) that carries electric power to the load. The connector live line supplies the electric power to the load from the power source. The connector live line is connected to the live line of the power source via a means (such as a plug) to supply power from the power source to the load.
As used herein, the term “connector neutral line” refers to a wire or cable (conductor) that completes the circuit between the load and power supply and carries back the electric current to the power source. The connector neutral line completes the electric circuit between the power source and the load (battery pack of the electric vehicle). The connector neutral line is connected to the neutral line of the power source to complete the electric circuit between the power source and the load.
As used herein, the term “connector earth line” refers to a wire or cable (conductor) that provides a low-resistance path for leakage current (fault current) to flow safely to the earth. The connector earth line is connected to the earth line of the power source to provide the low-resistance path for the leakage current (fault current) to flow safely to the earth.
As used herein, the term “low voltage power supply” refers to an electronic device inside the connector that provides low voltage power to the component of the connector. The low voltage power supply may comprise an X-rated capacitor to step down the voltage received from the power source.
As used herein, the term “visual indicator” refers to an indication device capable of emitting visual indication of any particular event. The visual indicator may include a light emitting diode, a display, and so forth capable of displaying visual indication indicating the presence of the earth line of the power source detected by the earth sensing module.
As used herein, the term “power source” refers to an equipment supplying AC power for charging the load (battery pack of the electric vehicle). The source may supply domestic AC power.
Figure 1, in accordance with an embodiment, describes electric vehicle charging connector 100. The connector 100 comprises a supply line 102, a leakage current sensing module 104, an earth sensing module 106, and a supply control module 108. The supply line 102 is configured to electrically connect a power source 110 to a load 112. The leakage current sensing module 104 is configured to detect a leakage current from the supply line 102. The earth sensing module 106 is configured to detect presence of an earth line 110a of the power source 110. The supply control module 108 is coupled with the supply line 102, the leakage current sensing module 104, and the earth sensing module 106. The supply control module 108 is configured to disconnect the power source 110 from the load 112 when the earth sensing module 106 fails to detect presence of the earth line 110a of the power source 110.
The present disclosure discloses the electric vehicle charging connector 100. The charging connector 100 as disclosed by the present disclosure is capable of fast charging battery pack of the electric vehicle. The charging connector 100 as disclosed by the present disclosure is advantageous in terms of detecting the presence of the earth line 110a of the power source 110. Beneficially, the charging connector 100 as disclosed by the present disclosure is advantageous in terms of displaying the presence of the earth line 110a. Beneficially, the charging connector 100 as disclosed by the present disclosure is advantageous in terms of not allowing the flow of power from the power source 110 to the load 112 (battery pack of the vehicle) for the proactive safety of the vehicle user. Beneficially, the charging connector 100 as disclosed by the present disclosure is advantageous in terms of eliminating any risk of electrocution of the vehicle user while charging the battery pack of the electric vehicle.
In an embodiment, the supply line 102 of the connector 100 comprises: a live line 102a, a neutral line 102b and an earth line 102c, of the connector 100. Beneficially, the live line 102a, the neutral line 102b and the earth line 102c, of the connector 100 enable the flow of power from the power source 110 to the load 112, completion of circuit between the power source 110 and load 112, and flow of leakage current to the earth, respectively. Beneficially, the supply line 102 of the connector 100 is capable of carrying large amount of power from the power source 110 to the load 112.
In an embodiment, the leakage current sensing module 104 comprises a zero-phase current transformer to detect the leakage current from the supply line 102. Beneficially, the zero-phase current transformer may be capable of detecting leakage current as low as 30mA. The leakage current sensing module 104 may be coupled with the supply control module 108. The supply control module 108 is configured to disconnect the power source 110 from the load 112 when the leakage current is detected by the leakage current sensing module 104.
In an embodiment, the leakage current sensing module 104 detects the leakage current by determining a current difference between the live line 102a and the neutral line 102b. Beneficially, the leakage current sensing module 104 is coupled with the live line 102a and the neutral line 102b. The leakage current sensing module 104 monitors the current flowing through the live line 102a and the neutral line 102b which would be equal in normal operating condition. In case of occurrence of any fault, the leakage current would be generated creating the current difference between the live line 102a and the neutral line 102b. The leakage current sensing module 104 determines the current difference between the live line 102a and the neutral line 102b to detect the leakage current.
In an embodiment, the supply control module 108 is configured to disconnect the power source 110 from the load 112, when the leakage current is detected. Beneficially, the power source 110 is disconnected from the load 112 to prevent any electrocution of the user of the electric vehicle. Beneficially, the connector 100 ensures the safety of the user of the electric vehicle.
In an embodiment, the supply control module 108 comprises a relay, wherein the relay is operated to disconnect the power source 110 from the load 112, when the leakage current is detected. Beneficially, the relay acts as a switch that opens or closes the circuit between the power source 110 and the load 112. It is to be understood that the relay of the supply control module 108 may be operated when the earth sensing module 106 fails to detect presence of the earth line 110a of the power source 110. Moreover, the relay of the supply control module 108 may also be operated when the leakage current sensing module 104 detects the leakage current.
In an embodiment, the earth sensing module 106 comprises an optocoupler to detect presence of the earth line 110a of the power source 110. Beneficially, the optocoupler of the earth sensing module 106 is fast-acting and quickly detects the presence of the earth line 110a of the power source 110.
In an embodiment, the connector 100 comprises a low voltage power supply 114 to power up at least one of: the leakage current sensing module 104, the earth sensing module 106, and the supply control module 108. Beneficially, the low voltage power supply 114 is a transformer-less step-down power supply.
In an embodiment, the connector 100 comprises a metal oxide varistor 116 configured to provide voltage surge protection to the at least one of: the leakage current sensing module 104, the earth sensing module 106, and the supply control module 108. Beneficially, the metal oxide varistor 116 protects the leakage current sensing module 104, the earth sensing module 106, and the supply control module 108 from voltage surges increasing the operational robustness of the connector 100.
In an embodiment, the connector 100 comprises at least one visual indicator 118 operable to display presence of the earth line 110a of the power source 110 detected by the earth sensing module 106. Beneficially, the visual indicator may indicate the presence of the earth line 110a of the power source 110 to the user of the vehicle. It is to be understood that based on the indication, the user may choose to change the power source and utilize a power source with proper earthing for enhanced safety of the user.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combinations of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, and “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings, and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. An electric vehicle charging connector (100), wherein the connector (100) comprises:
- a supply line (102) configured to electrically connect a power source (110) to a load (112);
- a leakage current sensing module (104) configured to detect a leakage current from the supply line (102);
- an earth sensing module (106) configured to detect presence of an earth line (110a) of the power source (110); and
- a supply control module (108) coupled with the supply line (102), the leakage current sensing module (104), and the earth sensing module (106),
wherein the supply control module (108) is configured to disconnect the power source (110) from the load (112) when the earth sensing module (106) fails to detect presence of the earth line (110a) of the power source (110).
2. The connector (100) as claimed in claim 1, wherein the supply line (102) of the connector (100) comprises: a live line (102a), a neutral line (102b) and an earth line (102c), of the connector (100).
3. The connector (100) as claimed in claim 1, wherein the leakage current sensing module (104) comprises a zero-phase current transformer to detect the leakage current from the supply line (102).
4. The connector (100) as claimed in claim 1, wherein the leakage current sensing module (104) detects the leakage current by determining a current difference between the live line (102a) and the neutral line (102b).
5. The connector (100) as claimed in claim 4, wherein the supply control module (108) is configured to disconnect the power source (110) from the load (112), when the leakage current is detected.
6. The connector (100) as claimed in claim 5, wherein the supply control module (108) comprises a relay, wherein the relay is operated to disconnect the power source (110) from the load (112), when the leakage current is detected.
7. The connector (100) as claimed in claim 1, wherein the earth sensing module (106) comprises an optocoupler to detect presence of the earth line (110a) of the power source (110).
8. The connector (100) as claimed in claim 1, wherein the connector (100) comprises a low voltage power supply (114) to power up at least one of: the leakage current sensing module (104), the earth sensing module (106), and the supply control module (108).
9. The connector (100) as claimed in claim 1, wherein the connector (100) comprises a metal oxide varistor (116) configured to provide voltage surge protection to the at least one of: the leakage current sensing module (104), the earth sensing module (106), and the supply control module (108).
10. The connector (100) as claimed in claim 1, wherein the connector (100) comprises at least one visual indicator (118) operable to display presence of the earth line (110a) of the power source (110) detected by the earth sensing module (106).