Patent ID: 12233731

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure includes many aspects and features. Moreover, while many aspects and features relate to, and are described in, the context of a field repairable and upgradable electric vehicle charger, embodiments of the present disclosure are not limited to use only in this context. The present disclosure can be understood more readily by reference to the following detailed description of the disclosure and the examples included therein.

Before the present articles, systems, apparatuses, and/or methods are disclosed and described, it is to be understood that they are not limited to specific methods unless otherwise specified, or to particular materials unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, example methods and materials are now described.

A. Definitions

It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” can include the aspects “consisting of” and “consisting essentially of.” Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.

As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “an opening” can include two or more openings.

Ranges can be expressed herein as from one particular value, and/or to another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent ‘about,’ it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.

As used herein, the terms “about” and “at or about” mean that the amount or value in question can be the value designated, some other value approximately or about the same. It is generally understood, as used herein, that it is the nominal value indicated ±10% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. It is understood that where “about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.

The terms “first,” “second,” “first part,” “second part,” and the like, where used herein, do not denote any order, quantity, or importance, and are used to distinguish one element from another, unless specifically stated otherwise.

As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase “optionally affixed to the surface” means that it can or cannot be fixed to a surface.

Moreover, it is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification.

Disclosed are the components to be used to manufacture the disclosed apparatuses, systems, and articles of the disclosure as well as the apparatuses themselves to be used within the methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these materials cannot be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular material is disclosed and discussed and a number of modifications that can be made to the materials are discussed, specifically contemplated is each and every combination and permutation of the material and the modifications that are possible unless specifically indicated to the contrary. Thus, if a class of materials A, B, and C are disclosed as well as a class of materials D, E, and F and an example of a combination material, A-D is disclosed, then even if each is not individually recited each is individually and collectively contemplated meaning combinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any subset or combination of these is also disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E would be considered disclosed. This concept applies to all aspects of this application including, but not limited to, steps in methods of making and using the articles and apparatuses of the disclosure. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of the disclosure.

It is understood that the apparatuses and systems disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions, and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.

With reference now to the drawings, and in particularFIG.1throughFIG.5thereof, examples of the field repairable and upgradable electric vehicle charger and the principles and concepts thereof will be described.

In an embodiment, a field repairable and upgradable electric vehicle charger implements an electric vehicle (EV) charger which distinctly includes charging circuits and internal electronics that are placed on a removable motherboard. The motherboard contains the charging circuits which receive energy from a source such as the electric grid and delivers it to the onboard battery of an electric vehicle. Thus, the disclosed embodiments realize a new approach in EV chargers by implementing removable components, such as a removable motherboard. Once removed, the motherboard can be repaired or replaced with an updated module, making the field repairable and upgradable electric vehicle charger retrofittable. Furthermore, the field repairable and upgradable electric vehicle charger, as disclosed herein, realizes a plethora of advantages associated with achieving modularity in charger components including the capability to repair and/or upgrade the field repairable and upgradable electric vehicle charger while the charger is currently installed and on a site.

In an embodiment, a real-time EV charger monitoring system is implemented as a comprehensive sensor system for monitoring the operational parameters of an EV charger in real-time during its operation to ensure that the EV charger is operating optimally. The real-time EV charger monitoring system can be utilized with the field repairable and upgradable electric vehicle charger, as disclosed herein. For example, the real-time EV charger monitoring system includes a plurality of sensors that collect real-time data from several components of the EV charger in manner that allows the system to obtain and analyze operational parameters indicating how the EV charger is currently operating. Thus, by actively monitoring the function of the EV charger in real-time while in use (e.g., real-time data collection and analysis), the real-time EV charger monitoring system can enhance the EV charger's charging efficiency, safety, and overall performance. Moreover, operational information for EV chargers that can be gleaned from the real-time EV charger monitoring system over time can be used to improve the design and development of EV chargers in a manner that improves on any degradation and failures detected after deployment (e.g., while the EV chargers are being used in the field), thereby providing better performance for EV chargers currently used in industry and in the future to progress the technology.

In order to combat negative impacts on the climate and cutting emissions associated with industry, transportation, motorized vehicles, etc., the development of new clean energy technologies has emerged. One such “clean energy” technology is electric vehicles (EVs), where EVs are designed to convert electrical energy (e.g., from a battery) into mechanical energy in a manner that eliminates the cost and unclean emissions related to gasoline fueling. An EV is defined as a vehicle that can be powered by an electric motor that draws electricity from a stored energy source, such as a rechargeable battery or fuel cell, and is capable of being charged from an external source. Some EVs are considered all-electric vehicles, being powered only by an electric motor that draws electricity from a battery. Other EVs are hybrids, where the vehicle can be powered by an electric motor that draws electricity from a battery and is also propelled by an internal combustion engine, such as a plug-in hybrid electric vehicle. EVs may realize a plethora of benefits, in addition to the environmental advantages (e.g., zero tailpipe emissions), including smooth electric performance, energy efficiency, convenience, and lower maintenance costs (e.g., fewer moving parts than gasoline vehicles).

Many EVs have batteries that are energy-dense lithium-ion type batteries. Typically, a bigger battery (measured in kilowatt-hours, or kWh) means more electric range. In general, EVs are cheaper to recharge in comparison to refueling gasoline vehicles. For instance, with every mile of driving, the cost of electricity to recharge an EV is typically a fraction of what that same mile would cost to refuel with gasoline. The battery of an EV can be recharged using an external source, also referred to as an EV charger (also referred to herein as a charging station). An EV charger (or electric vehicle supply equipment) is a piece of equipment that supplies electrical power for charging plug-in EVs. There are two main types of charging stations: AC charging stations and DC charging stations. Recharging an EV often involves inserting a charging plug from the charging station into the charge port of the EV. For example, the charging plug of the EV can be considered equivalent to a fuel nozzle at a gas station. Electrically recharging EVs provide several benefits over gasoline refueling, such as increased simplicity, cost-effectiveness, and convenience.

FIG.1depicts an example configuration of the field repairable and upgradable electric vehicle charger100. As disclosed herein, the field repairable and upgradable electric vehicle charger100implements an EV charger (or electric vehicle supply equipment), where the repairable and upgradable electric vehicle charger100functions as a piece of equipment that supplies electrical power for charging plug-in EVs. As a general description, the field repairable and upgradable electric vehicle charger100is electric vehicle supply equipment that is modularly designed, having at least one accessible compartment (e.g., removable container), and charging circuits and internal electronics that are implemented on a removable motherboard. The motherboard contains the charging circuits which receive energy from a source such as the electric grid and delivers it to the onboard battery of an electric vehicle. The invention represents a new approach in chargers by presenting a removable motherboard. Once removed, the motherboard can be repaired or replaced with an updated module, making the invention retrofittable. This can be done while the charger is installed and on a site. This modular architecture is centered on the removable motherboard container (3). The charger is mechanically de-energized by disconnecting the input power source (6). The charger can also be de-energized electronically through a signal sent wirelessly to the charging circuit via Bluetooth or Wi-Fi, among other processes and designs used in the current state of the art to de-energize live electric components. After de-energizing, the motherboard container (3) can be safely unscrewed and removed.

FIG.1illustrates an example configuration that is suitable for the field repairable and upgradable electric vehicle charger100to be employed as a Level 2 EV Charger. However, it should be understood that the example configuration for the field repairable and upgradable electric vehicle charger100shownFIG.1is not intended to be limiting and that the elements and functions of the disclosed embodiments can be applied to across a wide range of EV chargers in the industry having varying current (e.g., AC and DC) and voltage requirements. For example, it will be evident to one skilled in the art that the disclosed embodiments may accommodate the design and the power requirements (e.g., higher, or lower) of Level 1, Level 2 and Level 3 types of EV chargers without departing from the scope of the disclosure.

As background, EVs can be charged using EV chargers (or EVSE) operating at different charging speeds. For example, Level 1 EV chargers and Level 2 EV chargers are standard forms of electric vehicle supply equipment that are currently used in industry, distinguished by their charging speed, voltage, and the corresponding infrastructure that is required.

Level 1 EV chargers operate on a standard residential 120-V (120V) AC outlet and typically deliver power in a range of 1.4-1.9 kilowatts (kW). Generally, Level 1 EV chargers are the most basic and widely available form of EV charging and can be easily installed using a common (e.g., household) electrical outlet. However, due to its lower power output, Level 1 EV chargers function relatively slowly and may take several hours (e.g., overnight) to fully charge an electric vehicle, depending on its battery capacity. For example, Level 1 chargers can take 40-50+ hours to charge a Battery Electric Vehicle (BEV) to 80 percent from empty and 5-6 hours for a Plug-In Hybrid Electric Vehicle (PHEV). As previously described, the disclosed field repairable and upgradable electric vehicle charger100can be configured as a Level 1 EV charger in some embodiments, without departing from the scope of the disclosure.

Level 2 EV chargers offer high-rate AC charging for EVs (in comparison to Level 1 EV chargers). Level 2 EV chargers are configured to charge through 240V (in residential applications) or 208V (in commercial applications) electrical service, similar to that used for large appliances (e.g., electric stoves, dryers, etc.). Level 2 EV chargers can deliver power in a range of 7-19 kW, and provide significantly faster charging in comparison to Level 1 EV chargers. With Level 2 EV chargers, an EV can charge at a much higher rate, reducing the charging time to a few hours or less. For example, a Level 2 EV charger can charge a BEV to 80 percent from empty in 4-10 hours and a PHEV in 1-2 hours. Level 2 EV charging stations typically require professional installation, for instance by an electrician, and are commonly found in public charging stations, workplaces, and residential settings. Level 2 and Level 3 (described in detail in reference toFIG.3) equipment have been deployed at various public locations including, for example, at grocery stores, theaters, or coffee shops. Level 2 EV chargers differ from the aforementioned Level 1 EV chargers due to charging speed (e.g., power output) and voltage requirements. When selecting between Level 1 and Level 2 charger type for design and use, considerations can include voltages, resulting charging and vehicle dwell times, available infrastructure, individual charging needs, and estimated up-front and ongoing costs.

The field repairable and upgradable electric vehicle charger100implemented as a Level 2 EV charger, as shown inFIG.1, can be used as a charging station. For example, the field repairable and upgradable electric vehicle charger100can be installed as a wall-mounted or freestanding charging station. In operation, the field repairable and upgradable electric vehicle charger100acts as a fixed location for a user to come and plug-in their EV and receive the electrical power supplied (from the for field repairable and upgradable electric vehicle charger100) for charging their EV. The field repairable and upgradable electric vehicle charger100can comprise components (not shown inFIG.1) needed in order to function as a Level 2 EV charger, including but not limited to: a power supply (e.g., 208-240 V); and connectors (e.g., SAE11772 connector) which can be inserted directly into a charging port of an EV to facilitate the transfer of electrical power (between the charger100and the EV) that charges a battery of the EV.

FIG.1illustrates particular components of the field repairable and upgradable electric vehicle charger100that collectively achieve the EV charger's100distinct modular structure and EV charging capabilities. As seen inFIG.1, the disclosed field repairable and upgradable electric vehicle charger100comprises several components, including: a display screen1; attachment elements2shown as screws; removable motherboard container3; rack4; rack holder5; input power cable6; charging plug7; motherboard8; enclosure9; face10; and camera11.

The display1can be a digital display screen which presents visual information related to the operation of the field repairable and upgradable electric vehicle charger100, for instance displaying details and feedback that is associated with the EV charging process (e.g., charging status, charging rate, battery level, connector status, payment information, error messages, and the like). The display1may be implemented in accordance with various types of digital display technology, such as LCD (Liquid Crystal Display), LED (Light-Emitted Diode), OLED (Organic Light-Emitted Diode), touchscreen-capable, and the like. The size and shape of the display1may vary based on the specific application and design objectives of the field repairable and upgradable electric vehicle charger100.

As seen inFIG.1, the field repairable and upgradable electric vehicle charger100comprises a removeable motherboard container3. In the example ofFIG.1, the removeable motherboard container3has a substantially rectangular geometry, having an elongated flat bottom surface, two lateral surfaces, and no top surface such that the removeable motherboard container3is not enclosed and structured similar to a tray. Thus, the removeable motherboard container3has dimensions (e.g., length, width, height) and surfaces that form a shallow container suitable for stabling housing the internal electronic components that support the functionality of the field repairable and upgradable electric vehicle charger100.FIG.1illustrates that the removable motherboard container3is designed to hold the internal electronics of the field repairable and upgradable electric vehicle charger100, such as a motherboard, charging circuits, sensors, capacitors, resistors, integrated circuit chips such as microcontrollers and diodes, and other components as are typically required in the current state of the art EV charging circuits.

As will be described, the removeable motherboard container3functions as a physically separate module (contributing to the modular structure of the field repairable and upgradable electric vehicle charger100) that is designed to cooperatively interact with another module of the field repairable and upgradable electric vehicle charger100, namely the enclosure9. That is, the removeable motherboard container3is configured to be: coupled to the enclosure9, where it is arranged in an inserted position with the enclosure9such that the length of the removeable motherboard contained in placed inside of the enclosure9to stably hold and enclose the internal electronic components of the EV charger100therein; or decoupled from the enclosure9, where it is arranged in a removed position with the enclosure9such that the length removeable motherboard container3is outside of the enclosure9allowing the internal electronic components of the EV charger100to be easily accessed.

FIG.1depicts the enclosure9as another module of the field repairable and upgradable electric vehicle charger100, providing a main body for the EV charger's100structure. In the example ofFIG.1, the enclosure9has a substantially rectangular geometry, having surfaces, dimensions (length, width, height) and a substantively hollow internal area (e.g., compartment) that are suitable for the enclosure9to function as an enclosed compartment that houses the removable motherboard container3inside of its walls (e.g., surfaces) when the container3is coupled to the enclosure9in the inserted position. The enclosure9has an aperture along a lateral surface, where the aperture provides an opening to the enclosure9that receives the removable motherboard container3. For example, the removable motherboard container3can be slidably inserted (e.g., along the rack4) into the enclosure9and stably held inside of its compartment, where the enclosure9safely covers and stores the motherboard, circuits, and other internal electrical components that are contained therein. In this inserted position, the motherboard container3is fully coupled and enclosed inside of the enclosure9, having the length of the removable motherboard container3being positioned inside of the internal compartment of the enclosure9. When inserting the removable motherboard container3into the enclosure9, the container3can be slid along the rack4in a direction towards the enclosure9, until a lateral side of the container3is flush with the aperture, closing that surface wall of the enclosure9to fully enclose the internal electronics in the container3therein. The removable motherboard container3can stay in the inserted position with enclosure9while the field repairable and upgradable electric vehicle charger100is in use, for example during a charging process with an EV. Alternatively, the removable motherboard container3can be rearranged from the inserted position, where the container3is removed from the enclosure9while the field repairable and upgradable electric vehicle charger100remains essentially installed at the location as an EV charging station.

The removable motherboard container3is also configured to be decoupled (e.g., removed) from, or pulled out of, the enclosure9. For instance, the removable motherboard container3is structured to slide out through the aperture (e.g., along the rack4) of the enclosure9in a direction away from the body of the enclosure9. When the removable motherboard container3is slidably decoupled from the enclosure9, the length of the removable motherboard container3including the motherboard, circuits, and other electronic components are outside of the enclosure9. When the removable motherboard container3is in the fully removed position, all of the contents of the removable motherboard container3are outside of the enclosure's9compartment, which allows for the motherboard, circuits, and other electrical components held by the container3to be easily accessed for repairing, replacing, upgrading, or testing while the EV charger100is currently at its installation location and being actively used as an EV charging station. Consequently, the field repairable and upgradable electric vehicle charger100has a distinct structure comprised of interfacing modules3,9that allow the EV charger's100internal electronics to be safely enclosed (e.g., enclosure9) and removed (e.g., removable motherboard container3), even after the field repairable and upgradable electric vehicle charger100has been deployed.

Also,FIG.1shows that there are several components on the removable motherboard container3. In the example ofFIG.1, the removable motherboard container3has attachment elements2, shown as screws, that can be used to securely attached and/or detach the removable motherboard container3from the enclosure9. In an embodiment, the attachment elements2are screws designed with a proprietary head that requires a matching screwdriver to access them. The attachment elements2are positioned in each corner of the lateral surface that closes against the enclosure9, which allows the attachment elements2to be used to securely fasten the removable motherboard container3to the enclosure9when in the inserted positioned. In contrast, the attachment elements2can be loosened in order to detach the removable motherboard container3from the enclosure9. By loosening the screws, the removable motherboard container3can then be slidable moved out of the enclosure9and into the removed positioned where it is physically separated from the enclosure. The attachment elements2can be implemented as other forms of mechanical fastening mechanisms, including nails, bolts, nuts, clamps, anchors, rivets, as deems appropriate and/or suitable.

The removable motherboard container3has a rack4that is disposed along a bottom surface of the container3. The rack4can be structured as a protruding edge that serves as a rail mechanism to support the slidable movement of the removable motherboard container3. The rack4can be mated with a rack holder5attached to the enclosure9. For example, the rack holder5may be structured as having a groove (or trench) along a bottom internal surface of the enclosure9that mates and accepts the protruding edge of the rack4, in a manner that guides a horizontal movement of the removable motherboard container3. When the rack4of the removable motherboard container3is installed in the rack holder5, the container3can then move, sliding to be inserted and/or removed from the enclosure9.

FIG.1shows that there are several components on the enclosure9. The rack holder5is attached to the enclosure9and is configured to receive the rack4that is attached to the removable motherboard container3. The rack holder5can be formed using conductive materials such as copper among other metals and alloys, and could be secured within the enclosure9with magnets, hooks, and screws among other holding mechanisms to ensure stability.

As seen inFIG.1, a front-facing surface of the enclosure9is shown as a face10of the field repairable and upgradable electric vehicle charger100. The face10can be a surface of the field repairable and upgradable electric vehicle charger100that is intended to be visible and/or interactive for a user of the EV charge100. For example, the display1is attached to the face10to provide a screen on a surface of the EV charger100that is facing towards the user for greater visibility, for instance displaying information pertinent to the EV charging process to be viewed by the user.

An input power cable6is depicted as extending from the face10portion of the enclosure9. The input power cable6can be plugged into, or otherwise connected to, a power supply for the field repairable and upgradable electric vehicle charger100. In an embodiment, the input power cable6is connected to a power source such as the electric grid accessed through a wall outlet or electrical panel. In some embodiments, the input power cable6is connected to a power source that is integrated with the field repairable and upgradable electric vehicle charger100, such as a battery.

A charging plug7is also shown to extend from the face10portion of the enclosure9. For example, the charging plug7may be a charging cable or extension, having a connector at its distal end that can be inserted directly into a charging port of an EV allowing the end of the charging plug7to be plugged into EV. By coupling the charging plug7to an EV, a transfer of electrical power (e.g., AC power) is facilitated from the field repairable and upgradable electric vehicle charger100which supplies a charge to the EV's battery. Additionally,FIG.1also shows that a camera11may be implemented in the field repairable and upgradable electric vehicle charger100having a lens positioned at the face10of the enclosure9. The camera11enables image and/or video capture capabilities for the field repairable and upgradable electric vehicle charger100and may utilize a variation of lenses such as wide-angle lens among other types and variations of cameras.

Accordingly, the field repairable and upgradable electric vehicle charger100depicted inFIG.1realizes a modular architecture that allows portions of the EV charger100to be removed and re-inserted in a distinct manner. This modularity enables key components of the EV charger100, such as the motherboard, which may degrade over time, to be accessible in a manner that supports on-site repairs, replacements, or updates, thereby substantially reducing an amount of time that a field repairable and upgradable electric vehicle charger100has to be off-line (e.g., for repairs) in comparison to conventional EV chargers used in industry.

FIG.2depicts the field repairable and upgradable electric vehicle charger100, where the removeable motherboard container3is in a fully removed positioned. In operation, the field repairable and upgradable electric vehicle charger100can be mechanically de-energized by disconnecting the input power cable6in order to safely remove the removeable motherboard container3. The field repairable and upgradable electric vehicle charger100can also be de-energized electronically through a signal sent wirelessly to the charging circuit via Bluetooth or Wi-Fi, among other processes and designs used in the current state of the art to de-energize live electric components. After de-energizing, the removeable motherboard container3can be safely unscrewed and removed from the enclosure9of the field repairable and upgradable electric vehicle charger100.FIG.2illustrates that in the fully removed position, the entire length of the removable motherboard container3including the motherboard, circuits, and other electronic components are completely outside of the enclosure9allowing these elements to be easily accessible while the field repairable and upgradable electric vehicle charger100remains at its installed location and operating as an EV charging station.

FIG.3depicts a Level 3 EV charger300that can implement the field repairable and upgradable electric vehicle charger and functions as described above in reference toFIG.1. The Level 3 EV charger300may be deployed as a charging station that is located at a designated location, such as a parking garage, mall parking lot, or other public location deemed suitable for EV charging. Accordingly, the Level 3 EV charger3can include an EVSE port that provides the power to charge at least one vehicle, and houses one or more power connectors (or plugs) that are compatible to be connected with an EV. In use, a power connector from the Level 3 EV charger300can be plugged into an inlet of an EV's charging port (designed to accept the appropriate connector). By coupling the system's150connector to the vehicle's120charging port, a transfer of electrical power (e.g., DC power) is facilitated which supplies a charge (e.g., shown as dashed line arrow inFIG.1) to the vehicle's120battery. According to the embodiments, the Level 3 EV charger300acts a dedicated charging station, which includes one or more field repairable and upgradable electric vehicle chargers, as disclosed herein, integrated into its architecture, and operates in accordance with fast charging and/or DC fast charging standards.

The Level 3 EV charger300, also referred to as a DC fast charger, can function as a high-power charging station that is capable of providing a significantly faster charging experience compared to Level 1 EV chargers and Level 2 EV chargers. Through DC fast charging, the Level 3 EV charger300can provide as much as 350 kW or more of power and fully charge an EV in as quickly as 15 minutes.

FIG.4depicts a real-time EV charger monitoring system400for monitoring the operational parameters of an EV charger410in real-time during its operation to ensure that the EV charger410is operating optimally. In the example ofFIG.4, the real-time EV charger monitoring system400is utilized with the field repairable and upgradable electric vehicle charger410, as disclosed herein.FIG.4illustrates the real-time EV charger monitoring system400including a plurality of sensors420that are integrated within the field repairable and upgradable electric vehicle charger410in order to collect real-time measurement data from several components of the EV charger410. Thus, by obtaining real-time data from the sensors420, the real-time EV charger monitoring system400can obtain and analyze the real-time values for different operational parameters of the EV charger410that indicate how the EV charger410is currently operating.

For example, the sensors420obtain data in real-time that is associated with operational parameters related to the EV charging functions of the EV charger410, including temperature, power consumption, current flow, and the like. According to the embodiments, the sensors420are configured to continuously obtain measurements from the internal elements (e.g., hardware, electronics, etc.) of the EV charger410and/or obtain measurements pertaining to the external environment surrounding the EV charger410in real-time (e.g., per-second) or at another defined time intervals. The sensors420can obtain measurements of the external environment surrounding the EV charger410such as moisture levels, external noise, temperature, dust, force, and the like. By monitoring the external environment of the EV charger410, the real-time EV charger monitoring system400can assess how characteristics outside of the EV charger410structure can impact its performance, such as the EV charger's410resilience to different weather conditions and evaluating of the impact of noise, for instance, where this information can ultimately be leveraged to facilitate design improvements for the EV charger410like more durable and environmentally charging stations.

The real-time EV charger monitoring system400also includes a real-time EV charger monitoring controller430. In the example ofFIG.4, the real-time EV charger monitoring controller430is implemented as a computer device, such as a laptop computer, that is communicatively connected to the sensors420of the system400. The EV charger monitoring controller430may communicate with the sensors420via wireless networking technology, such as Wi-Fi, Bluetooth, etc. Alternatively, the sensors420are connected to the real-time EV charger monitoring controller430via wire technology, such as a physical USB connection. Thus, the real-time EV charger monitoring controller430can receive the real-time data collected by the sensors420, namely the operational parameters of the EV charger410, in order to conduct further analysis. The real-time EV charger monitoring controller430can include computer hardware devices, including elements such as processor(s), central processing units(s) (CPU) or controller(s), memory that is programmed to perform the real-time monitoring functions. In an embodiment, the real-time EV charger monitoring system400is implemented as a computer device that is integrated within the hardware of the EV charger410itself.

For example, while the EV charger410is currently operating to charge a plugged-in EV, the real-time EV charger monitoring controller430can continuously receive data from the sensors420in real-time as a mechanism to monitor its current operational status. Furthermore, the real-time EV charger monitoring controller430analyzes the real-time data from sensors420to determine whether the measured operational parameters present any indication that the EV charger410is having anomalous operations, for instance operating outside of its nominal limits (e.g., errors, failures, degradation, etc.). For example, sensors420may be placed at the charging contacts (e.g., connectors) of the EV charger410which measure a temperature at the contact interface between the EV and the EV charger410in real-time throughout the EV charging process. The real-time EV charger monitoring controller430receives the real-time temperature measurements collected by the sensors420, and subsequently monitors and analyzes the temperature operational parameter of the EV charger410in a manner that allows the real-time EV charger monitoring controller430to detect whether there are unusually high heat levels at the contact interface between the EV and the EV charger410. In an embodiment, the real-time EV charger monitoring controller430is configured to utilize artificial intelligence (AI)/machine learning (ML) approaches to monitor and analyze the operational parameters of the EV charger410. For example, real-time EV charger monitoring controller430can train AI/ML models over time using the real-time data collect from sensors420at the EVB charger410to be able to learn trends and predictively determine that an operational parameter is reaching and may exceed its proper limits (indicating anomalous operations).

Referring back to the previous example, in the case where the real-time EV charger monitoring controller430determines that there are dangerously high temperatures at the EV charger410during charging, the current status of that operational parameter can be an indication that there is EV charger410is having anomalous operations, particularly severe overheating problem at the EV charger410which requires immediate action, such as disconnection from the EV, shut-down of the EV charger410, and/or repair of components at the EV charger410. In an embodiment, the EV charger monitoring controller430is also configured to perform automatic corrective actions, in response to monitoring the operational parameters of the EV charger410. For instance, the EV charger monitoring controller430can have the ability to automatically adjust the operation of the EV charger410, regulating temperature (e.g., triggering cooling functions, decrease charging rate, etc.) at the EV charger410as result of monitoring high temperature conditions at the EV charger410. In some embodiments, the EV charger monitoring controller430may be configured to execute other corrective actions related to the real-time monitoring of the operational parameters of the EV charger410, such as optimizing charging algorithms and/or hardware enhancements, and automatically alerting maintenance personnel in the event of a detected operational problem to prevent damage (e.g., to the EV and/or the EV charger410) or safety risks.

Thus, by actively monitoring the function of the EV charger410in real-time, the real-time EV charger monitoring system400can enhance the EV charger's charging efficiency, safety, and overall performance. Moreover, operational information for EV chargers that can be gleaned from the real-time EV charger monitoring system over time can be used to improve the design and development of EV chargers in a manner that improves on any degradation and failures detected after deployment (e.g., while the EV chargers are being used in the field), thereby providing better performance for EV chargers currently used in industry and in the future to progress the technology.

FIG.5depicts a block diagram of an example computer system500in which the disclosed aspects of the field repairable and upgradable electric vehicle charger and/or the real-time EV charger monitoring system may be implemented. Furthermore, it should be appreciated that although the various instructions are illustrated as being co-located within a single processing unit, there may be some implementations in which processor(s) includes multiple processing units, allowing one or more instructions may be executed remotely from the other instructions.

The computer system500includes a bus502or other communication mechanism for communicating information, one or more hardware processors504coupled with bus512for processing information. Hardware processor(s)504may be, for example, one or more general purpose microprocessors.

The computer system500also includes a main memory506, such as a random-access memory (RAM), cache and/or other dynamic storage devices, coupled to bus502for storing information and instructions to be executed by processor504. Main memory506also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processor504. Such instructions, when stored in storage media accessible to processor504, render computer system500into a special-purpose machine that is customized to perform the operations specified in the instructions.

The computer system500further includes a read only memory (ROM)508or other static storage device coupled to bus502for storing static information and instructions for processor504. A storage device510, such as a magnetic disk, optical disk, or USB thumb drive (Flash drive), etc., is provided and coupled to bus502for storing information and instructions.

The computer system500may be coupled via bus502to a display512, such as a liquid crystal display (LCD) (or touch screen), for displaying information to a computer user. An input device514, including alphanumeric and other keys, is coupled to bus502for communicating information and command selections to processor504. Another type of user input device is cursor control516, such as a mouse, a trackball, or cursor direction keys for communicating direction information and command selections to processor504and for controlling cursor movement on display512. In some embodiments, the same direction information and command selections as cursor control may be implemented via receiving touches on a touch screen without a cursor.

The computing system500may include a user interface module to implement a GUI that may be stored in a mass storage device as executable software codes that are executed by the computing device(s). This and other modules may include, by way of example, components, such as software components, object-oriented software components, class components and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuitry, data, databases, data structures, tables, arrays, and variables.

In general, the word “component,” “engine,” “system,” “database,” data store,” and the like, as used herein, can refer to logic embodied in hardware or firmware, or to a collection of software instructions, possibly having entry and exit points, written in a programming language, such as, for example, Python, Ruby on Rails or NodeJS. A software component may be compiled and linked into an executable program, installed in a dynamic link library, or may be written in an interpreted programming language such as, for example, BASIC, Perl, or Python. It will be appreciated that software components may be callable from other components or from themselves, and/or may be invoked in response to detected events or interrupts. Software components configured for execution on computing devices may be provided on a computer readable medium, such as a compact disc, digital video disc, flash drive, magnetic disc, or any other tangible medium, or as a digital download (and may be originally stored in a compressed or installable format that requires installation, decompression or decryption prior to execution). Such software code may be stored, partially or fully, on a memory device of the executing computing device, for execution by the computing device. Software instructions may be embedded in firmware, such as an EPROM. It will be further appreciated that hardware components may be comprised of connected logic units, such as gates and flip-flops, and/or may be comprised of programmable units, such as programmable gate arrays or processors.

The computer system500may implement the techniques described herein using customized hard-wired logic, one or more ASICs or FPGAs, firmware and/or program logic which in combination with the computer system causes or programs computer system2400to be a special-purpose machine. According to one embodiment, the techniques herein are performed by computer system500in response to processor(s)504executing one or more sequences of one or more instructions contained in main memory506. Such instructions may be read into main memory506from another storage medium, such as storage device510. Execution of the sequences of instructions contained in main memory506causes processor(s)504to perform the process steps described herein. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions.

The term “non-transitory media,” and similar terms, as used herein refers to any media that store data and/or instructions that cause a machine to operate in a specific fashion. Such non-transitory media may comprise non-volatile media and/or volatile media. Non-volatile media includes, for example, optical or magnetic disks, such as storage device510. Volatile media includes dynamic memory, such as main memory506. Common forms of non-transitory media include, for example, a floppy disk, a flexible disk, hard disk, solid state drive, magnetic tape, or any other magnetic data storage medium, a CD-ROM, any other optical data storage medium, any physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, NVRAM, any other memory chip or cartridge, and networked versions of the same.

Non-transitory media is distinct from but may be used in conjunction with transmission media. Transmission media participates in transferring information between non-transitory media. For example, transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise bus502. Transmission media can also take the form of acoustic or light waves, such as those generated during radio-wave and infra-red data communications.

The computer system500also includes a communication interface518coupled to bus502. Network interface518provides a two-way data communication coupling to one or more network links that are connected to one or more local networks. For example, communication interface518may be an integrated services digital network (ISDN) card, cable modem, satellite modem, or a modem to provide a data communication connection to a corresponding type of telephone line. As another example, network interface518may be a local area network (LAN) card to provide a data communication connection to a compatible LAN (or WAN component to communicate with a WAN). Wireless links may also be implemented. In any such implementation, network interface518sends and receives electrical, electromagnetic or optical signals that carry digital data streams representing various types of information.

A network link typically provides data communication through one or more networks to other data devices. For example, a network link may provide a connection through local network to a host computer or to data equipment operated by an Internet Service Provider (ISP). The ISP in turn provides data communication services through the world wide packet data communication network now commonly referred to as the “Internet.” Local networks and Internet both use electrical, electromagnetic or optical signals that carry digital data streams. The signals through the various networks and the signals on network link and through communication interface518, which carry the digital data to and from computer system510, are example forms of transmission media.

The computer system500can send messages and receive data, including program code, through the network(s), network link and communication interface518. In the Internet example, a server might transmit a requested code for an application program through the Internet, the ISP, the local network and the communication interface518.

The received code may be executed by processor504as it is received, and/or stored in storage device510, or other non-volatile storage for later execution. In various implementations, operations that are performed “in response to” or “as a consequence of” another operation (e.g., a determination or an identification) are not performed if the prior operation is unsuccessful (e.g., if the determination was not performed). Operations that are performed “automatically” are operations that are performed without user intervention (e.g., intervening user input). Features in this document that are described with conditional language may describe implementations that are optional. In some examples, “transmitting” from a first device to a second device includes the first device placing data into a network for receipt by the second device, but may not include the second device receiving the data. Conversely, “receiving” from a first device may include receiving the data from a network, but may not include the first device transmitting the data.

Each of the processes, methods, and algorithms described in the preceding sections may be embodied in, and fully or partially automated by, code components executed by one or more computer systems or computer processors comprising computer hardware. The one or more computer systems or computer processors may also operate to support performance of the relevant operations in a “cloud computing” environment or as a “software as a service” (SaaS). The processes and algorithms may be implemented partially or wholly in application-specific circuitry. The various features and processes described above may be used independently of one another, or may be combined in various ways. Different combinations and sub-combinations are intended to fall within the scope of this disclosure, and certain method or process blocks may be omitted in some implementations. The methods and processes described herein are also not limited to any particular sequence, and the blocks or states relating thereto can be performed in other sequences that are appropriate, or may be performed in parallel, or in some other manner. Blocks or states may be added to or removed from the disclosed example embodiments. The performance of certain of the operations or processes may be distributed among computer systems or computer processors, not only residing within a single machine, but deployed across a number of machines.

While the specification includes examples, the disclosure's scope is indicated by the following claims. Furthermore, while the specification has been described in language specific to structural features and/or methodological acts, the claims are not limited to the features or acts described above. Rather, the specific features and acts described above are disclosed as examples for embodiments of the disclosure.

Insofar as the description above and the accompanying drawing disclose any additional subject matter that is not within the scope of the claims below, the disclosures are not dedicated to the public and the right to file one or more applications to claims such additional disclosures is reserved.