Patent Publication Number: US-2021184478-A1

Title: Charging apparatus and control method thereof

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is based on and claims priority under 35 U.S.C. § 119 to Korean Patent Application No. 10-2019-0168180, filed on Dec. 16, 2019, in the Korean Intellectual Property Office, the disclosure of which is incorporated by reference herein in its entirety. 
     BACKGROUND 
     1. Field 
     The disclosure relates to a charging apparatus and a control method thereof, and more particularly, to a charging device and a control method capable of adjusting the intensity of a charging current according to an input power source using a single cable. 
     2. Description of the Related Art 
     In a conventional method of charging an electric vehicle or a hybrid vehicle, there are a method of charging using a charging station and a method of charging using a portable power cord. 
     In order to charge an electric vehicle or a hybrid vehicle using the above two methods, a user needs to have two types of charging cables. 
     In a case where charging an electric vehicle or a hybrid vehicle using a portable power cord, a lot of charging time is required due to a low charging current, and a user needs to move to a charging station for fast charging. 
     In addition, as two types of cables are alternately mounted, the durability of the cables is reduced. 
     SUMMARY 
     It is an aspect of the disclosure to provide a charging apparatus including a controller capable of determining a connected power source using a single cable and adjusting the intensity of a charging supply current, and a control method thereof. 
     It is another aspect of the disclosure to provide a charging apparatus including a waterproof and durable power source connector, and a control method thereof. 
     Additional aspects of the disclosure will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the disclosure. 
     In accordance with an aspect of the disclosure, a charging apparatus includes a first power source connector connectable to a charging station power source, a second power source connector connectable to a commercial power source, a cable connected to the first power source connector and the second power source connector, and a controller including a power source terminal connected to the first power source connector or the second power source connector via the cable and controlling the intensity of a charging supply current when the first power source connector or the second power source connector is connected to the power source terminal. 
     The controller may be configured to determine an intrinsic resistance value of the connected power source and adjust the intensity of the charging supply current based on the determination result. 
     The controller may be configured to monitor a state of being charged by the charging supply current. 
     The charging apparatus may further include a charge breaker, wherein the controller may be configured to determine the monitoring result and control the charge breaker to stop charging when it is determined that charging is complete. 
     The controller may be configured to accept a charging supply current of  32 A and determine the charging supply current. 
     The controller may be configured to accept a charging supply voltage of 110V to 230V and determine the charge supply voltage. 
     The first power source connector and the second power source connector each may include a cover having a screw thread. 
     The cover may include a waterproof material. 
     The first power source connector and the second power source connector may be provided to be cross-detachable. 
     The charging apparatus may further include a communication device communicating with the charge breaker, wherein the controller may be configured to control the charge breaker to supply a charging current based on a communication result of the communication device. 
     In accordance with an aspect of the disclosure, a control method of a charging apparatus includes connecting at least one of a first power source connector and a second power source connector to at least one of a charging station power source and a commercial power source, determining a power source connector connected to the power source among the first power source connector and the second power source connector by a controller, and controlling to adjust the intensity of a charging supply current based on the determination result. 
     The controlling may include determining an intrinsic resistance value of the connected power source and adjusting the intensity of the charging supply current based on the determination result. 
     The controlling may include monitoring a state of being charged by the charging supply current. 
     The controlling may include determining the monitoring result and controlling a charge breaker to stop charging when it is determined that charging is complete. 
     The controlling may include accepting a charging supply current of  32 A and determining the charging supply current. 
     The controlling may include accepting a charging supply voltage of 110V to 230V and determining the charge supply voltage. 
     The controlling may include controlling a duty ratio of a charge breaker signal when the second power source connector is connected to the power source. 
     The controlling may include changing the duty ratio based on a user input, wherein the control method may further include changing the intensity of the charging supply current when the duty ratio is changed. 
     The controlling may include stopping control of the duty ratio when the first power source connector is connected to the power source. 
     The control method may further include communicating with the charge breaker, wherein the controlling may include controlling the charge breaker to supply a charging current based on a communication result. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       These and/or other aspects of the disclosure will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which: 
         FIG. 1  illustrates a vehicle, a power source, and a charging apparatus according to an embodiment of the disclosure; 
         FIG. 2  is a control block diagram of the charging apparatus according to an embodiment of the disclosure; 
         FIG. 3  is a detailed charging system configuration diagram of the charging apparatus according to an embodiment of the disclosure; 
         FIG. 4  is a flowchart illustrating processes in which a controller of the charging apparatus according to an embodiment of the disclosure adjusts the intensity of a charging supply current; 
         FIG. 5  is a flowchart illustrating processes in which the controller of the charging apparatus according to an embodiment of the disclosure monitors the charging supply current; 
         FIGS. 6A, 6B, and 6C  illustrate processes of connecting a power source connector to the controller of the charging apparatus according to an embodiment of the disclosure; and 
         FIG. 7  illustrates a waterproof structure of the power source connector of the charging apparatus according to an embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Like reference numerals refer to like elements throughout the specification. This specification does not describe all the elements of the embodiments, and duplicative contents between general contents or embodiments in the technical field of the present disclosure will be omitted. The terms ‘part,’ module, ‘member,’ and ‘block’ used in this specification may be embodied as software or hardware, and it is also possible for a plurality of ‘parts,’ ‘modules,’ ‘members,’ and ‘blocks’ to be embodied as one component, or one ‘part,’ ‘module,’ ‘member,’ and ‘block’ to include a plurality of components according to embodiments. 
     Throughout the specification, when a part is referred to as being “connected” to another part, it includes not only a direct connection but also an indirect connection, and the indirect connection includes connecting through a wireless network. 
     Also, when it is described that a part “includes” an element, it means that the element may further include other elements, not excluding the other elements unless specifically stated otherwise. 
     Throughout the specification, when a member is described as being “on” another member, this includes not only a case where one member is adjacent to the other member, but also a case where another member is placed between the two members. 
     The terms ‘first,’ ‘second,’ etc. are used to distinguish one element from another element, and the elements are not limited by the above-mentioned terms. 
     The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. 
     In each step, an identification numeral is used for convenience of explanation, the identification numeral does not describe the order of the steps, and each step may be performed differently from the order specified unless the context clearly states a particular order. 
     Hereinafter the disclosure will be described in detail with reference to the accompanying drawings. 
       FIG. 1  illustrates a vehicle  1 , a power source  2 , and a charging apparatus  3  according to an embodiment of the disclosure. 
     Referring to  FIG. 1 , the vehicle  1  may include an electric vehicle, a hybrid vehicle, or a plug-in hybrid vehicle. 
     The power source  2  may be a charging station power source or a commercial power source. The commercial power source may have a voltage value of 110V to 230V used in a general home. 
     The charging apparatus  3  includes a power source connector  100 , a controller  200 , a cable  201 , and a charging connector  300 . The charging apparatus  3  may further include a charge breaker  400  or a communication device  500 . 
       FIG. 2  is a control block diagram of the charging apparatus  3  according to an embodiment of the disclosure, and  FIG. 3  is a detailed charging system configuration diagram of the charging apparatus  3  according to an embodiment of the disclosure. 
     Referring to  FIG. 2 , the charging apparatus  3  may include a first power source connector  101  that may be connected to a charging station power source, a second power source connector  102  that may be connected to a commercial power source, the controller  200 , the charging connector  300 , the charge breaker  400  or the communication device  500 . 
     The first power source connector  101  according to an embodiment of the disclosure may be connected to a power source provided in a charging station, and the second power source connector  102  may be connected to a commercial power source. The first power source connector  101  may withstand a higher voltage than the second power source connector  102 . In addition, the first power source connector  101  and the second power source connector  102  are provided to be cross-detachable depending on the type of the power source  2 . 
     Voltages that may be accepted by the first power source connector  101  and the second power source connector  102  may be 110V to 230V, but are not limited thereto. 
     A current that may be accepted by the first power source connector  101  may be up to  32 A, and a current that may be accepted by the second power source connector  102  may be up to  12 A, but are not limited thereto. 
     The structures of the first power source connector  101  and the second powersource connector  102  will be described later with reference to  FIGS. 5 and 6 . 
     Referring to  FIG. 3 , the power source connector  100  is connected to the controller  200 , and the controller  200  is connected to the charging connector  300 . 
     The controller  200  may include a micro controller unit (MCU) and the charge breaker  400 . 
     The charge breaker  400  may control a CP circuit  401  or a relay  402  provided in the controller  200 . Specifically, when it is determined that the first power source connector  101  is connected to the power source  2 , the controller  200  controls the charge breaker  400  not to generate a CP signal, and as a result, the CP circuit  401  is opened, and the relay  402  is connected. 
     When the second power source connector  102  is connected, the controller  200  may control the charge breaker  400  so that the CP circuit  401  is connected. 
     The cable  201  according to an embodiment of the disclosure connects the controller  200  to the first power source connector  101  or the second power source connector  102 . A voltage that may be accepted by the cable  201  may be 110V to 230V, but is not limited thereto. 
     The controller  200  according to an embodiment of the disclosure includes a power source terminal connected to a first power source connector  101  or the second power source connector  102  via a cable  201  and adjusts the intensity of a charging supply current when the first power source connector  101  or the second power source connector  102  is connected to the power source terminal. 
     The controller  200  may determine an intrinsic resistance of the connected power source  2 , and determine the connected power source  2  based on the determination result. 
     Specifically, according to an embodiment of the disclosure, the first power source connector  101  may have an intrinsic resistance value of 3 kΩ, and the second power source connector  102  may have an intrinsic resistance value of 1 kΩ. 
     When the first power source connector  101  according to an embodiment of the disclosure is connected to the power source  2 , the controller  200  may distribute the voltage based on the intrinsic resistance value of the first power source connector  101 . 
     Specifically, referring to  FIG. 3 , the controller  200  may set a reference voltage Vref and include a reference resistance (Ref resistance). The reference resistors present inside the power source connector  100  and the controller  200  may be connected in series. 
     According to an embodiment of the disclosure, in a case where the reference voltage is 5V and the reference resistance is 1 kΩ, when the first power source connector  101  having the intrinsic resistance value of 3 kΩ is connected to the power source  2 , a voltage of 3.75V may be distributed to the first power source connector  101 . 
     Also, when the second power source connector  102  having the intrinsic resistance value of 1 kΩ is connected to the power source  2 , a voltage of 2.5 V may be distributed to the second power source connector  102 . 
     However, the above-described voltage values are only an example, and may vary depending on the voltage applied to the power source  2 . 
     When it is determined that the first power source connector  101  is connected to the power source  2 , the controller  200  may block the control signal and allow charging of the vehicle  1 . 
     When the second power source connector  102  according to an embodiment of the disclosure is connected to the power source  2 , the controller  200  may distribute the voltage based on the intrinsic resistance value of the second power source connector  102 . 
     The controller  200  may convert a voltage value into a digital signal. For example, the controller  200  may utilize an analog-to-digital converter (ADC), and when the input voltage is alternating current, may convert it into direct current to set a reference voltage. 
     When it is determined that the second power source connector  102  is connected to the power source  2 , the controller  200  may adjust a duty ratio of a CP signal or a relay signal. 
     When charging starts, the controller  200  may adjust the current supplied to the vehicle  1  by adjusting the duty ratio of the CP signal or the relay signal. 
     The controller  200  may adjust the intensity of the charging supply current based on the connected power source  2  and monitor a state of being charged by the charging supply current. 
     A voltage that may be accepted by the controller  200  may be 110V to 230V, but is not limited thereto. A current that may be accepted by the controller  200  may be up to  32 A, but is not limited thereto. 
     The controller  200  according to an embodiment of the disclosure may include the charge breaker  400  and communicate with the charge breaker  400 . The controller  200  may control the supply of the charging supply current through the control of the charge breaker  400 . 
     The controller  200  may be implemented as a memory (not shown) for storing an algorithm for controlling the operation of components in the charging apparatus  3  or data for a program reproducing the algorithm and a processor (not shown) for performing the above-described operations using data stored in the memory. The memory may be implemented as a separate chip from the processor, and may be implemented as a single chip with the processor. 
     The charging connector  300  according to an embodiment of the disclosure is connectable to the vehicle  1  and connects the controller  200  to the vehicle  1 . The voltage that the charging connector  300  may accept may be 110V to 230V, but is not limited thereto. A current that the charging connector  300  may accept may be up to  32 A, but is not limited thereto. 
     The charge breaker  400  according to an embodiment of the disclosure communicates with the controller  200  and adjusts the supply of charging current, 
     The charge breaker  400  may control the CP circuit  401  or the relay  402 , but is not limited thereto. A signal of the charge breaker  400  may be the CP signal or the relay signal, but is not limited thereto. 
     Specifically, when the second power source connector is connected to the power source  2 , the charge breaker  400  may adjust the supply current through duty ratio control. The controller  200  may monitor the state of charge by PWM control of the charge breaker  400 . 
     The communication device  500  according to an embodiment of the disclosure allows communication of information on the charging supply current between the controller  200  and the charge breaker  400 . The information on the charging supply current may be whether charging is completed, the intensity of the charging supply current or the intensity of a charging supply voltage, whether a circuit is abnormal, or whether normal charging is performed, but is not limited thereto. 
     The communication device  500  may include one or more components that enable communication with an external device, and may include, for example, at least one of a short range communication module, a wired communication module, and a wireless communication module. 
     At least one component may be added or removed corresponding to the performance of the components of the charging apparatus  3  illustrated in  FIGS. 1 to 3 . It will be readily understood by those skilled in the art that the mutual location of components may be changed in consideration of the performance or structure of the system. 
     The respective components illustrated in  FIG. 2  refers to software and/or hardware components such as a field programmable gate array (FPGA) and an application specific integrated circuit (ASIC). 
       FIG. 4  is a flowchart illustrating processes in which the controller  200  according to an embodiment of the disclosure adjusts the intensity of a charging supply current. 
     Referring to  FIG. 4 , the controller  200  determines whether the power source  2  is connected to the first power source connector  101  or the second power source connector  102  and determines the type of the connected power source connector at  2101  and  2102 . 
     Specifically, the controller  200  may determine whether the first power source connector  101  is connected to the power source  2  or the second power source connector  102  is connected to the power source  2 , based on the intrinsic resistance value of the connected power source  2 . 
     When it is determined that the first power source connector  101  is connected to the power source  2 , the controller  200  determines the charging supply current according to a first mode at  2103  and  2104 . 
     Specifically, when it is determined that the first power source connector  101  is connected to the power source  2 , the controller  200  recognizes as the first mode and may transmit the information of the power source  2  to the vehicle  1 . When the vehicle  1  receives the information of the power source  2  corresponding to the first mode, the controller  200  may supply a current of  32 A to the vehicle  1 . 
     Referring to  FIG. 3 , the controller  200  may block the CP signal and connect the relay  402  to adjust the magnitude of current. According to an embodiment of the disclosure, when the controller  200  blocks the CP signal and connects the relay  402 , a high current may be supplied to the vehicle  1 . 
     However, when it is determined that the power source  2  is not connected to the first power source connector  101 , the controller  200  determines the charging supply current according to a second mode at  2105 . 
     Specifically, when it is determined that the second power source connector  102  is connected to the power source  2 , the controller  200  recognizes as the second mode, and may supply a current of  12 A, which is a current corresponding to the second mode, to the vehicle  1 . The controller  200  may control a PWM duty ratio of the CP circuit  401  or the relay  402 . 
     When a user inputs an appropriate current value, the controller  200  may transmit a CP signal or a relay signal having a duty ratio corresponding to the appropriate current to the vehicle  1 . The appropriate current may be determined by the user&#39;s input. For example, the appropriate current may be determined according to an appropriate current change instruction input through a current conversion input unit provided outside the charging apparatus  3 . 
     For example, the controller  200 , based on a commercial power source value, may set the current intensity to  12 A when a value of the PWM duty ratio is 20%, the current intensity to  10 A when a value of the PWM duty ratio is 16.66%, the current intensity to  8 A when a value of the PWM duty ratio is 13.33%, the current intensity to  7 A when a value of the PWM duty ratio is 11.66%, or the current intensity to  6 A when a value of the PWM duty ratio is 10%. However, the current intensity is not limited thereto, and may vary depending on the voltage of the power source  2 . 
     When the user inputs a desired current intensity, the controller  200  may control the duty ratio of the CP circuit  401  or the relay  402  to generate a current of the intensity input by the user. 
     When the charging supply current is determined, the controller  200  performs charging at  2106 . 
       FIG. 5  is a flowchart illustrating processes in which the controller  200  of the charging apparatus  3  according to an embodiment of the disclosure monitors the charging supply current. 
     Referring to  FIG. 5 , when the intensity of the charging supply current is determined as illustrated in  FIG. 4 , the controller  200  performs charging according to the determined charging supply current at  2201 . 
     The controller  200  may monitor whether charging is completed, the intensity of the charging supply current or the intensity of the charging supply voltage, whether the circuit is abnormal, or whether normal charging is performed, but is not limited thereto. 
     When it is determined that charging of the vehicle  1  is completed, the controller  200  controls the charge breaker  400  at  2202  and  2203 . 
     Specifically, when it is determined that charging of the vehicle  1  is completed, the controller  200  controls the charge breaker  400  to open the CP circuit  401  or the relay  402  and controls the current not to flow. However, when it is determined that charging of the vehicle  1  is not completed, the controller  200  continuously performs charging according to the charging supply current. 
     Also, when it is determined that charging of the vehicle  1  is completed, the controller  200  stops charging and ends the charging process at  2204 . 
       FIGS. 6A to 6C  illustrate processes of connecting the power source connector  100  to the controller  200  of the charging apparatus  3  according to an embodiment of the disclosure. 
     Referring to  FIG. 6A , the controller  200  may be connected to the power source connector  100  through a screw structure. 
     Specifically, the controller  200  includes a screw thread  1001  and a male terminal  1002 , and the power source connector  100  includes a cover  1003  coupled with the screw thread  1001  provided on the controller  200  and a female terminal  1004 . The power source connector  100  includes the first power source connector  101  or the second power source connector  102 . 
     Referring to  FIG. 6B , the male terminal  1002  provided on the controller  200  may be coupled with the female terminal  1004  provided on the power source connector  100 . 
     Referring to  FIG. 6C , the screw thread  1001  provided on the controller  200  may be coupled with the cover  1003  provided on the power source connector  100 . Through this process, the controller  200  and the power source connector  100  have a double coupling structure, and as a result, the durability is improved. The cover  1003  may include a waterproof material. 
       FIG. 7  illustrates a waterproof structure of the power source connector  100  of the charging apparatus  3  according to an embodiment of the disclosure. 
     Referring to  FIG. 7 , the controller  200  and the power source connector  100  may be coupled through a double coupling structure. 
     As described above, the male terminal  1002  provided on the controller  200  may be coupled to the female terminal  1004  provided on the power source connector  100 , and in addition to the above coupling structure, the screw thread  1001  provided on the controller  200  may be coupled to the cover  1003  provided on the power source connector  100 . 
     The disclosed embodiments may be implemented in the form of a recording medium storing instructions executable by a computer. The instructions may be stored in the form of program code, and when executed by a processor, a program module may be created to perform the operations of the disclosed embodiments. The recording medium may be implemented as a computer-readable recording medium. 
     The computer-readable recording medium includes various kinds of recording media in which instructions which may be decrypted by a computer are stored. For example, there may be a ROM (Read Only Memory), a RAM (Random Access Memory), a magnetic tape, a magnetic disk, a flash memory, an optical data storage device, and the like. 
     As is apparent from the above, a charging apparatus according to an embodiment of the disclosure can improve the convenience of charging by using a single cable. 
     Further, the charging apparatus according to an embodiment of the disclosure can improve durability by including a cable connector having a waterproof structure. 
     While the disclosure has been particularly described with reference to exemplary embodiments, it should be understood by those of skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the disclosure.