DRY CONTACT-BASED AUTOMATIC ALIGNMENT OF ELECTRIC VEHICLE (EV) CHARGING LOAD TO WHOLE CIRCUIT CONSUMPTION

20250065746

18/455687

August 25, 2023

A system for dry contact-based automatic alignment of electric vehicle (EV) charging load to whole circuit consumption comprises an electric vehicle supply equipment (EVSE) including a charger relay circuit, a dry contact input and a current transformer (CT) clamp that is installed on an external electrical circuit to be measured against. The CT clamp outputs a signal that can be calibrated to generate an analog signal that passes a minimum threshold of the dry contact input. Normally the inputs at the dry contact input in the EVSE are programmed. A logic behind the external electrical circuit is modified to: a) turn off delivery of power to the EV when a calibrated current on the CT clamp is exceeded b) turn back on power to the EV if the calibrated current is no longer exceeded for over X seconds.

Siemens Industry, Inc. (Alpharetta, GA, US)

1. A system comprising: an electric vehicle supply equipment (EVSE) including a charger relay circuit and a dry contact input to receive inputs; a current transformer (CT) clamp that is installed on an external electrical circuit to be measured against, wherein the CT clamp outputs a signal that can be calibrated to generate an analog signal that passes a minimum threshold of the dry contact input, wherein normally the inputs at the dry contact input in the EVSE are programmed to serve a safety bypass of the EVSE that allows the external electrical circuit to shutdown the charger relay circuit, requiring plugging and unplugging an electric vehicle (EV) to restart charging, and wherein a logic behind the external electrical circuit is modified to: a) turn off delivery of power to the EV when a calibrated current on the CT clamp is exceeded b) turn back on power to the EV if the calibrated current is no longer exceeded for over X seconds.

2. The system of claim 1, wherein the X seconds is a programmable value.

3. The system of claim 2, wherein a large enough threshold is important to prevent situations of motorboating.

4. The system of claim 1, wherein the CT clamp outputs an analog voltage through a wire proportional to a current passing through the external electrical circuit.

5. The system of claim 4. wherein the CT clamp can be adjusted in amplitude, to reach a voltage that triggers a dry input digital output to be a 1 at a certain current level flowing through the circuit, e.g., 200A.

6. A system comprising: an electric vehicle supply equipment (EVSE) including a charger relay circuit and a dry contact input to receive inputs; a current transformer (CT) clamp that is installed on an external electrical circuit to be measured against, wherein to ensure a continuity of operation, a two-step approach can be used: a) a large-step-down, b) an adaptable-step-up, wherein in a modified algorithm, instead of closing a relay, the EVSE reduces a current by a large step and then verifies whether the dry contact input still indicates a reduction is needed, if a further reduction is needed, then an additional large step is performed, wherein a size of the additional large step is determined depending on a maximum charger current and local regulation for how long an overcurrent protection device needs to turn current off wherein a different, smaller step down could be chosen depending on a jurisdiction and the EVSE, wherein after a step down triggered by a change in rest-of-building consumption, the EVSE waits always configurable X seconds before attempting a step up, wherein the adaptable-step-up works in a discovery mode, to try to maximize the current allocated to an EV, slowly and safely, wherein an algorithm starts with a step-up that is 50% of the step-down, if there is an indication from the CT of overload in less than X seconds from the step-up, the step-up value is changed to 50% of the previous step-up value, wherein an adjustment exercise continues until a dry contact interrupt is gone for more than X seconds, and wherein at this point, a load is “aligned to a building” and if an alignment to the load of the building is achieved at less than a maximum charger current for Y seconds (configurable value), the EVSE attempts a step-up again, starting from 50% of the step-down value, until a steady state is reached such that the algorithm repeats throughout a charging session.

7. The system of claim 6, wherein if an AC charger can deliver 40A per phase, a 10A step-down guarantees that the AC charger will inform the EV to reduce current through a control pilot within less than 5 seconds, if it waits for results of a command to the EV to reduce current for 1 second.

8. The system of claim 7, wherein in the example of the 10A step-down, a 5A step-up would be a first attempt.

9. The system of claim 8, wherein a 5A step-down could be chosen for a 32A EVSE.

10. The system of claim 9, wherein if a 5A initial step-up would trigger a dry contact interrupt, a current would be reduced by 3A.

11. A system for dry contact-based automatic alignment of electric vehicle (EV) charging load to whole circuit consumption, the system comprising: a) an electrical circuit, to which an electric vehicle supply equipment (EVSE) and rest of a home are connected; b) a circuit breaker limited to a predetermined amount of current; c) a current transformer (CT) clamp, which: a. is attached to the electrical circuit, and b. outputs an analog voltage through a wire proportional to the current passing through the electrical circuit, and can be adjusted in amplitude, to reach a current level that triggers a dry input digital output to be a 1 at a certain current level flowing through the electrical circuit; c. has means for an adjustable current setpoint level; d) a wire connecting between the CT clamp and the dry input on the EVSE; e) the EVSE with: a. a dry input contact with an isolated reading, b. an electromechanical relay that can be turned on/off, and c. a microcontroller; f) the microcontroller inside the EVSE that: a. senses a dry input isolated output, b. is able to advertise a maximum current to the EV while charging through a control pilot (PWM signal), powerline communications, and c. is able to shutdown current altogether by controlling the electromechanical relay to be on/off, wherein when the EVSE receives a voltage through the dry input contact it indicates that the electrical circuit has reached its maximum rated amperage (over current), wherein the EVSE sends a OA command to an EV (or shuts down the electromechanical relay), and wherein an over current state is reset if a cable is unplugged from the EV.

12. The system of claim 11, wherein the circuit breaker is limited to the predetermined amount of current.

13. The system of claim 12, wherein to reach the voltage that triggers the dry input digital output to be a 1 at a certain current level of current flowing through the electrical circuit.

14. The system of claim 11. wherein the dry input contact with the isolated reading (input is analog, output is digital, can be 0 or 1).

15. The system of claim 11, wherein the microcontroller senses a dry input isolated output (0 or 1).

16. A system for dry contact-based automatic alignment of electric vehicle (EV) charging load to whole circuit consumption, the system comprising: a) an electrical circuit, to which an electric vehicle supply equipment (EVSE) and rest of a home are connected; b) a circuit breaker limited to a predetermined amount of current; c) a current transformer (CT) clamp, which: a. is attached to the electrical circuit, and b. outputs an analog voltage through a wire proportional to the current passing through the electrical circuit, and can be adjusted in amplitude, to reach a current level that triggers a dry input digital output to be a 1 at a certain current level flowing through the electrical circuit; c. has means for an adjustable current setpoint level; d) a wire connecting between the CT clamp and the dry input on the EVSE; e) the EVSE with: a. a dry input contact with an isolated reading, b. an electromechanical relay that can be turned on/off, and c. a microcontroller; f) the microcontroller inside the EVSE that: a. senses a dry input isolated output, b. is able to advertise a maximum current to the EV while charging through a control pilot (PWM signal), powerline communications, and c. is able to shutdown current altogether by controlling the electromechanical relay to be on/off, wherein the EVSE receives a voltage through the dry input contact and indicates that the electrical circuit has reached its maximum rated amperage (over current), the EVSE reduces an amount of current allocated to the EV by large steps, until the dry input contact input no longer indicates that a maximum current has been reached, and wherein, at that point, the EVSE increases the current by a variable amount, smaller than a large step, in attempts to reach a current level that will be as high as possible without triggering an over current indication from the dry input contact.

17. The system of claim 16, wherein the circuit breaker is limited to the predetermined amount of current.

18. The system of claim 17, wherein to reach the voltage that triggers the dry input digital output to be a 1 at a certain current level of current flowing through the electrical circuit.

19. The system of claim 16, wherein the dry input contact with the isolated reading (input is analog, output is digital, can be 0 or 1).

20. The system of claim 16, wherein the microcontroller senses a dry input isolated output (0 or 1).

60; 60; 02; 02

edspap.20250065746