AN ELECTRONIC PROTECTION DEVICE FOR AN ELECTRIC VEHICLE CHARGING
DEVICE DESCRIPTION
The present invention relates to the field of electric vehicle charging devices.
More particularly, the present invention relates to an electronic protection device for an electric vehicle charging device, such as a charging pole or an on board charger for electric vehicles.
As is known, an electric vehicle, e.g. electric car, typically comprises a storage battery to supply the electric power needed for the functioning of the electric motor and the other components of the electric vehicle.
Since the storage battery of an electric vehicle has a relatively short operative autonomy, charging devices have been developed to allow the storage battery of the electric vehicle to be charged by an external power source.
Electric vehicle charging devices may comprise fixed charging arrangements, such as a charging pole.
A charging pole is electrically connectable to an electric vehicle for providing the electric power needed to charge the storage battery.
A charging pole generally comprises an electric power supplying line that is electrically connected with an electric power source, such as the mains or another power distribution network, so as to make available an AC supplying voltage, normally at 110-240 V, for charging the storage battery.
Electric vehicle charging devices may also comprise charging arrangements that are installed on board an electric vehicle, such as an on board charger.
Typically, an on board charger comprises an electric transformer, which has a primary winding electrically connected with an on board electric power supplying line, and a secondary winding electrically connected with a rectifying circuit that is in turn electrically connected with the storage battery on board the electric vehicle.
During the charging process of the storage battery, the on board supplying line is electrically connected with the electric power source, possibly through a charging pole, so as provide the electric transformer with the AC supplying voltage supplied by the electric power source. The electric transformer, in turn, outputs an AC voltage having a suitable voltage level, normally around 400V.
The rectifying circuit of the on board charger receives the AC voltage provided by the secondary winding of the electric transformer and outputs a DC voltage suitable to charge the storage battery.
In traditional charging devices, relatively poor performances in terms of protection from electric faults are typically provided during the charging process of the storage battery.
In a traditional charging pole, protection from electric faults is merely ensured by protection devices installed in the mains or in the power distribution network, with which the charging pole is electrically connected.
Traditional on board chargers generally provide no active protection functionalities against electric faults.
A protection against electric faults is given by the electric transformer, which ensures a galvanic insulation between the storage battery and the electric power source.
Unfortunately, due to the presence of such an electric transformer, current on board charging devices are typically relatively heavy and cumbersome with the consequence that their installation on electric vehicles, in which no large installation volumes are generally available, is often difficult and time consuming.
Therefore, the main aim of the present invention is to provide a protection device for an electric vehicle charging device, which allows the overcoming of the drawbacks mentioned above.
Within this aim, it is an object of the present invention to provide a protection device, which ensures improved performances in terms of protection against electric fault conditions, at least during the charging process of the storage battery.
A further object of the present invention is to provide a protection device, which can be easily installed in charging poles and on board chargers for electric vehicles.
A further object of the present invention is to provide a protection device, which is easy to manufacture at industrial level, at competitive costs.
Thus, the present invention provides an electronic protection device for an electric vehicle charging device, according to the following claim 1.
Such an electric vehicle charging device comprises at least an electric power supplying line for providing a storage battery that is on board an electric vehicle with electric power supplied by an electric power source that is outside said electric vehicle.
The electronic protection device, according to the invention, is configured to receive data/information related to a possible electric fault condition, identify an electric fault
condition on the basis of said data/information and interrupt said electric power supplying line, when an electric fault condition is identified.
Preferably, the electronic protection device, according to the invention, comprises:
at least one pair of electric contacts, which are electrically connected with said power supplying line and arranged to be mutually coupled with or separated from one another; control means that are configured to receive said data/information related to a possible electric fault condition, identify an electric fault condition on the basis of said data/information and generate a tripping signal, when an electric fault condition is identified;
actuating means for separating said electric contacts upon the receiving of said tripping signal, thereby interrupting said electric power supplying line.
According to an embodiment of the invention, said control means are capable of communicating with first sensing means that are configured to detect the presence of an earth leakage current, said control means generating said tripping signal when an electric fault condition is identified on the basis of first data/information received from said first sensing means.
Preferably, said first sensing means are integrated in an envelope of the electronic protection device.
According to another embodiment, said control means are capable of communicating with a control device of said storage battery, which is installed on board said electric vehicle and is configured to check the insulation status of the storage battery, said control means generating said tripping signal when an electric fault condition is identified on the basis of second data/information received from said control device.
According to a further embodiment, said control means are capable of communicating with second sensing means of the current flowing along the electric power supplying line of the electric vehicle charging device, said control means generating a tripping signal when an electric fault condition is identified on the basis of third data/information received from said second sensing means.
Preferably, said second sensing means are integrated in an envelope of the electronic protection device.
According to another embodiment, said control means comprise processing means for providing metering data/information related to the electric insulation status of said electric vehicle charging device and/or said storage battery.
In yet a further embodiment, said control means comprise a communication interface for communicating with a remote system or device, possibly on board the electric vehicle or remotely positioned therefrom.
According to an embodiment of the present invention, the electronic protection device is suitable to be operatively associated with or integrated in an on board charger for electric vehicles.
Such an on board charger comprises a first electric power supplying line, which is electrically connected with said storage battery and is configured to be electrically connected with said electric power source, during a charging process of said storage battery.
The electronic protection device is capable of receiving data/information related to a possible electric fault condition, identifying an electric fault condition on the basis of said data/information and interrupting said first electric power supplying line, when an electric fault condition is identified.
According to a further embodiment of the present invention, the electronic protection device is suitable to be operatively associated with or integrated in a charging pole for electric vehicles.
Such a charging pole comprises a second electric power supplying line, which is electrically connected with said electric power source and is configured to be electrically connected with said storage battery, during a charging process of said storage battery.
The electronic protection device is capable of receiving data/information related to a possible electric fault condition, identifying an electric fault condition on the basis of said data/information and interrupting said second electric power supplying line, when an electric fault condition is identified.
The charging device, according to the invention, ensures advanced performances in terms of protection against electric fault conditions.
In fact, the electronic protection device, according to the invention, ensures an electrical insulation between the storage battery of the electric vehicle and the electric power source, if a fault condition is identified during or before a charging process of the storage battery of the electric vehicle.
Advantageously, the electronic protection device, according to the invention, may be configured to ensure protection against earth leakage currents, insulation problems of the storage battery, short circuit faults and over-currents.
Protection interventions are actively managed by the control means of the electronic protection device on the basis of data/information related to possible fault conditions that may
occur at the on board charger, at the storage battery, at the charging pole and/or at the electric power source.
The adoption of the electronic protection device, according to the invention, on an on board charger allows to remarkably reducing the weight and size of this latter with respect to traditional chargers, since it is possible to avoid the installation of the electric transformer. The adoption of the electronic protection device, according to the invention, on a charging pole for electric vehicles ensures improved protection performances with respect to common protection devices comprised in the mains or the electric power distribution network to which the charging pole is electrically connected.
Protection interventions may in fact be commanded by the control means of the electronic protection device on the basis of data/information, which relate to components (e.g. the storage battery) of the electric vehicle and which can be received directly from the electric vehicle.
The electronic protection device, according to the invention, has a simple structure and is relatively easy and cheap to manufacture at industrial level and install on the field.
Further features and advantages of the present invention will become apparent from the following description of preferred embodiments, taken in conjunction with the attached figures, in which:
- Fig. 1 is a schematic diagram of the electronic protection device, according to the invention;
- Fig. 2 is a schematic diagram of an on board charger for electric vehicles, which comprises the electronic protection device, according to the invention;
- Fig. 3 is a schematic diagram of an charging pole for electric vehicles, which comprises the electronic protection device, according to the invention.
Referring now to the cited figures, the present invention relates to an electronic protection device 10 for an electric vehicle charging device 1 A, IB.
The electric vehicle charging device 1A, IB comprises an electric power supplying line 5, 6 for charging a storage battery 2 that is on board an electric vehicle 100 (e.g. an electric car) with electric power supplied by a power source 50.
For the sake of simplicity, the electronic protection device 10 will be hereinafter described with reference to the case in which the supplying line 5, 6 is a single-phase electric line.
Of course, the supplying line 5, 6 may be of a multi-phase type, such as a three-phase electric line.
The external power source 50 is placed outside the electric vehicle and it may be, for example, the mains or another electric power distribution network. The power source 50 provides an AC voltage VIN, typically at 1 10-240 V.
According to the invention, the protection device 10 is arranged so as to be capable of receiving data/information S I , S2, S3 related to a possible electric fault condition, identifying an electric fault condition on the basis of the received data/information S I , S2, S3 and interrupting the supplying line 5, 6, when an electric fault condition is identified.
The protection device 10 is thus capable of electrically insulating the storage battery 2 from the electric power source 50, when it identifies an electric fault condition on the basis of the received data/information S I , S2, S3.
Preferably, the protection device 10 comprises at least one pair of electric contacts 1 10, electrically connected with the power supplying line 5, 6 and arranged to be mutually coupled with or separated from one another.
Preferably, the protection device 10 comprises also control means 120, e.g. a microprocessor, that are configured to receive the data/information S I , S2, S3.
On the basis of the data/information S I , S2, S3, the control means 120 are capable of identifying a fault condition and generating a tripping signal T.
Preferably, the protection device 10 comprises actuating means 130 that are capable of separating the electric contacts 1 10 when they receive the tripping signal T generated by the control means 120.
Preferably, the electric contacts 1 10 and the actuating means 130 may be integrated in an electric contactor or a circuit breaker that is electrically connected with the supplying line 5, 6.
The actuating means 130 may comprise a relay that is capable of performing the separation of the contacts 1 10 on the basis of the tripping signal T.
Other solutions are possible, according to the needs.
The control means 120 and/or the actuating means 130 may be powered by the supplying line 5, 6 or by a further power supply, according to the needs. This further facilitates the operative installation of the protection device 10.
Preferably, the control means 120 of the protection device 10 are capable of communicating with first sensing means 140.
The communication between the control means 120 and the first sensing means 140 may advantageously occur through suitable 12-24V communication lines or a serial communication bus.
The first sensing means 140 are configured to detect the presence of an earth leakage current IE and generate a first signals S I indicative of the presence of the earth leakage current IE. The term "earth leakage current" identifies any current circulating towards earth that is generated by a malfunction at the power supplying line 5, 6 or at any electric loads connected thereto, for example the storage battery 2.
The first sensing means 140 may comprise a current transformer, in which the primary winding is formed a couple of conductors (e.g. a phase conductor and the neutral conductor) of the power supplying line 5, 6.
If the currents flowing along said conductors are not balanced, the secondary winding of the current transformer 140 generates a current signal S I , which is thus indicative the presence of an earth leakage current.
Alternatively, the first sensing means 140 may also comprise other sensing circuitry that is arranged to ensure higher resolution and accuracy with respect to a current transformer.
In line of principle, the first sensing means 140 may be positioned in a remote position with respect to the electronic protection device 10.
Preferably, as shown in figure 3, the first sensing means 140 are integrated within an envelope 1 1 of the electronic protection device 10.
Advantageously, the control means 120 receive the first sensing signal S I and check whether a fault condition is present on the basis of the first data/information S I provided by the first sensing means 140.
The control means 120 preferably check whether the earth leakage current overcomes a first predefined threshold value VTHI, e.g. 6mA. However, different criteria may be adopted to identify a fault condition.
Once a fault condition is identified, the control means 120 generate the tripping signal T, thereby determining the interruption of the supplying line 5, 6.
Preferably, the control means 120 are capable of communicating with a control device 21 of the storage battery 2, which is installed on board the electric vehicle 100.
The communication between the control means 120 and the control device 21 may advantageously occur through suitable 12-24V communication lines or a serial communication bus.
The control device 21 is configured to check the insulation status of the storage battery 2 and generate a sensing signal S2 that is indicative of said insulation status.
Preferably, the control device 21 is configured to calculate the impedance between the storage battery 2 and the ground level.
The control device 21 may comprise measuring circuits (not shown) to detect the presence of DC leakage currents generated by the storage battery 2. Said measuring circuits may be arranged to detect, for example:
- the presence a first DC leakage current IL1 flowing between the storage battery 2 and a member of the electric vehicle, e.g. the chassis; or
- the presence of a second DC leakage current IL2 flowing between a couple of electric terminals of the storage battery 2; or
- the presence of a third DC leakage current IL3 flowing along the supplying line 5, 6. The control means 120 receive the second sensing signal S2 and check whether a fault condition is present on the basis of the second data/information S2 provided by the control device 21.
In order to identify an electric fault condition, the control means 120 may check whether the calculated impedance value is lower than a predefined value or said DC leakage currents ILI- IL3 overcome a predefined threshold value Vxm, e.g. 6mA.
Also in this case, different criteria may be adopted to identify an electric fault condition.
If a fault condition is identified, the control means 120 generate the tripping signal T, thereby determining the interruption of the supplying line 5, 6.
Preferably, the control means 120 of the protection device 10 are capable of communicating with second sensing means 150, which may comprise, for example, a current sensor of the known type.
The second sensing means 150 may be positioned in a remote position with respect to the electronic protection device 10 or, as shown in figure 3, preferably be integrated within the envelope of the electronic protection device 10.
The communication between the control means 120 and the first sensing means 140 may advantageously occur through suitable 12-24V communication lines or a serial communication bus.
The second sensing means 150 are configured to detect the current ICH flowing along the power supplying line 5, 6, namely the current that charges the storage battery 2.
The control means 120 receive third/data information S3 that said indicative of the current ICH and check whether a fault condition is present on the basis of the first data/information SI provided by the first sensing means 140.
The control means 120 preferably check whether the current ICH overcomes a predefined threshold value ITH3, e.g. equal to 1,1-1,2 ICH-
However, different criteria may be adopted to identify a fault condition.
Once a fault condition is identified, the control means 120 generate the tripping signal T, thereby determining the interruption of the supplying line 5, 6.
Thanks to the second sensing means 150, the protection device 10 is capable of providing protection against over-currents flowing along the supplying line 5, 6.
The functioning of the protection device 10 is quite simple and effective.
During the charging process of the storage battery 2, the control means 120 continuously process the data/information SI, S2, S3 related to possible fault condition and provided by the first sensing means 140, the control device 21 and/or the second sensing means 150.
When a fault condition is identified, the control means generate the tripping signal T for activating the actuating means 130 and interrupting the power supplying line 5, 6, thereby electrically insulating the storage battery 2 from the external power source 50.
The protection device 10 may advantageously exert its protection functionalities also before a charging process of the storage battery 2 is performed.
If a fault condition is identified on the basis of the data/information SI, S2, and/or S3, the protection device 10 may immediately operate the interruption of the power supplying line 5, 6 even if an electrical connection between the electric power source 50 and the storage battery 2 is not yet established.
The protection device 10 is thus capable of preventing from the execution of a charging process of the storage battery 2.
The protection device 10 may advantageously exert metering functionalities, so as to facilitate the avoiding of electrical faults and the scheduling of maintenance interventions on the electric vehicle.
To this aim, the control means 120 may advantageously comprise processing means 121 for processing the received data/information SI, S2, S3 and providing metering data/information M related to the electric insulation status of the whole charging system including the electric vehicle charging device and the storage battery 2.
The control means 120 of the protection device 10 may provide additional processing functionalities of the data/information provided by the first sensing means 140 and the control device 21.
According to a preferred embodiment of the invention, the control means 120 are provided with a communication interface 122 for communicating with a remote system or device 170 through suitable 12-24V communication lines or a serial communication bus.
The remote system or device 170 may for example be placed on board the electric vehicle 100 (such as the control unit of the electric vehicle) or remotely with respect to sadi electric vehicle and the charging pole IB.
Other solutions are possible, according to the needs.
The electronic protection device 10 may comprise or associated with a further protection arrangement 160 that is configured to provide an automatic protection against short circuit faults. The protection arrangement 160 may comprise for example a magneto-thermal circuit breaker.
The protection arrangement 160 may be positioned remotely with respect to the protection device 10 or be integrated within its envelope 1 1.
It is apparent how this solution allows to further improving the protection performances provided by the electronic protection device 10.
In an embodiment of the present invention, the electronic protection device 10 is operatively associated with or integrated in an on board charger 1 A for electric vehicles.
The charger 1A is suitable to be installed on board the electric vehicle 100, so as to charge a storage battery 2 thereof with electric power supplied by the electric power source 50.
The charger 1A may advantageously comprise an electronic switching converter 13 that is electrically connected with the storage battery 2 and provides an output voltage VDC2, preferably a DC voltage, for charging said storage battery.
Preferably, the switching converter 13 comprises a cascade of electronic stages 13 1 - 133.
A first rectifying stage 13 1 , for example a diode bridge, receives the AC input voltage VIN provided by the external power source 50 and outputs a first rectified DC voltage VDCI -
A switching stage 132 receives the first rectified voltage VDCI and provides an adjustable AC voltage VACI -
A second rectifying stage 133 receives the adjustable AC voltage VACI and outputs an adjustable second rectified DC voltage VDC2, which is the output voltage provided by the switching converter 13 for charging the storage battery 2.
Normally, the output voltage VDC2 is around 400V. However, such an output voltage is adjustable by varying the switching frequency of the switching stage 132.
The charger 1 A can thus be easily configured to charge storage batteries of different types. The charger 1A comprises also a first electric power supplying line 5 that is electrically connected with the storage battery 2 and is configured to be electrically connected with the electric power source 50, during a charging process of the storage battery 2.
In particular, the supplying line 5 electrically connects the switching converter 13 (and the storage battery 2) with the electric power source 50, during a charging process of the storage battery 2.
Preferably, the supplying line 5 is provided with a first plug arrangement 51, which allows the connection with a supplying cable (not shown).
The supplying line 5 may be directly connected with the external power source 50 via said supplying cable, during a charging process of the storage battery 2.
Alternatively, as shown in figure 2, the supplying line 5 may be connected with a charging pole IB, via the mentioned supplying cable, said charging pole being in turn electrically connected with the power source 50 through another electric power supplying line 6.
A communication channel 91, for example suitable 12-24V communication lines or a serial communication bus, may be advantageously established between the storage battery 2 (and/or the on board charger 1 A) and the charging pole IB, during the charging process.
According to the invention, the electronic protection device 10 is capable of receiving data/information SI, S2, S3 related to a possible electric fault condition, identifying an electric fault condition and interrupting the supplying line 5, when an electric fault condition is identified.
In another embodiment of the present invention, the electronic protection device 10 is operatively associated with or integrated in a charging pole IB for electric vehicles.
The charging pole IB is electrically connected with the power source 50 through the second electric power supplying line 6.
The supplying line 6 is provided with a second plug arrangement 61, which allows the connection with a supplying cable (not shown).
The supplying line 6 is advantageously configured to be electrically connected with the storage battery 2 of the electric vehicle 100, during a charging process of the storage battery 2.
In particular, the supplying line 6 is configured to be electrically connected with the supplying line 5 of a charger 1A installed on board the electric vehicle 100, as shown in figure 3.
The supplying line 6 is thus capable of providing the on board charger 1A with the electric power supplied by the power source 50, during a charging process of the storage battery 2. According to the invention, the electronic protection device 10 is capable of receiving data/information SI, S2, S3 related to a possible electric fault condition, identifying an electric fault condition and interrupting the supplying line 6, when an electric fault condition is identified.
It is to be noticed the feature that, even when operatively associated with or integrated in a charging pole IB, the protection device 10 is capable of receiving the data/information S2 and S3, indicative of the insulation status of the storage battery 2 and the amount of current ICH flowing towards the storage battery 2.
Once the charging pole IB is electrically connected with the storage battery 2 to charge this latter, the protection device 10 is in fact capable of communicating with the control device 21 or with the sensing means 150 or with another device 170 on board the electric vehicle 100. To this aim, a communication channel 91, for example suitable 12-24V communication lines or a serial communication bus, may be established between the storage battery 2 (and/or the on board charger 1 A) and the charging pole IB.
This solution is quite advantageous, since it allows to greatly powering the protection and metering functionalities that can be made available by the protection device 10.
The electronic protection device 10, according to the present invention, fully allows the achievement of the intended aims and objects.
The protection device 10 is capable of providing improved functionalities in terms of protection from electric faults, in particular ensuring robust interruption functionalities, even in tough operative conditions and with a wide temperature range.
The protection device 10 is capable of promptly reacting to the presence of electric fault conditions with predefined constant intervention times.
The control means 120 of the protection device 10 ensures a remarkable operative flexibility and allows to easily adapting the operative functioning of the protection device 1 according to the needs.
The protection device 10 has a relatively simple structure, which is easy to manufacture and install on an electric vehicle, at competitive costs.