Electric vehicle docking connector with embedded EVSE controller

An electric vehicle supply equipment (EVSE) kit for charging an electric vehicle through a charging port of the electric vehicle, comprising an EVSE controller configured to:

• a) monitor a sensed utility supply voltage;
• b) determine whether the sensed utility voltage is closer to a first level or a second level;
• c) establish an allowable voltage range based upon which level is determined for the sensed utility voltage;
• d) set a maximum current limit in accordance with the allowable voltage range based upon a predetermined correlation;
• e) adjust a control pilot pulse duty cycle to a level corresponding the maximum current limit;
• f) monitor a current flow and the sensed utility voltage;
• g) generate a fault alarm and trouble code if the current flow is above the maximum current limit;
• and
• h) generate a fault alarm and trouble code if the sensed voltage utility voltage deviates outside the allowable range.

A method for an electric vehicle supply equipment (EVSE) controller in an EVSE kit for charging an electric vehicle through a charging port of the electric vehicle, the method comprising:

• a) monitoring a sensed utility supply voltage;
• b) determining whether the sensed utility voltage is closer to a first level or a second level;
• c) establishing an allowable voltage range based upon which level is determined for the sensed utility voltage;
• d) setting a maximum current limit in accordance with the allowable voltage range based upon a predetermined correlation;
• e) adjusting the control pilot pulse duty cycle to a level corresponding the maximum current limit;
• f) monitoring a current flow and the sensed utility voltage;
• g) generating a fault alarm and trouble code if the current flow is above the maximum current limit;
• and
• h) generating a fault alarm and trouble code if the sensed voltage utility voltage deviates outside the allowable range.

An electric vehicle supply equipment (EVSE) kit for charging an electric vehicle (EV) through a charging port of the electric vehicle, comprising an EVSE controller configured to:

• a) perform a handshake with the electric vehicle using a prescribed handshake protocol via a control pilot conductor after a docking connector has been inserted into the charging port of the EV;
• b) set the duty cycle of the control pilot generator to a predetermined maximum allowable current draw;
• c) compare a sample of a present temperature inside the EVSE to a predetermined threshold temperature;
• d) allow the predetermined maximum allowable current draw if the sample of the present temperature inside the EVSE is below the predetermined threshold temperature;
• e) compare the sample of the present temperature inside the EVSE with a maximum allowable operating temperature;
• f) reduce the duty cycle by a factor proportional to at least one of:
• (1) either the ratio between the sample of the present temperature and the maximum allowable operating temperature;
• or (2) the difference between the sample of the present temperature and the maximum allowable operating temperature if the sample of the present temperature is less than the maximum operating temperature;
• and
• g) halt charging if the sample of the measured temperature exceeds the maximum operating temperature.

A method for an electric vehicle supply equipment (EVSE) controller in an EVSE kit for charging an electric vehicle through a charging port of the electric vehicle, the method comprising:

• a) performing a handshake with the electric vehicle using a prescribed handshake protocol via a control pilot conductor after a docking connector has been inserted into the charging port of the EV;
• b) setting the duty cycle of the control pilot generator to a predetermined maximum allowable current draw;
• c) comparing a sample of a present temperature inside the EVSE to a predetermined threshold temperature;
• d) allowing the predetermined maximum allowable current draw if the sample of the present temperature inside the EVSE is below the predetermined threshold temperature;
• e) comparing the sample of the present temperature inside the EVSE with a maximum allowable operating temperature;
• f) reducing the duty cycle by a factor proportional to at least one of:
• (1) either the ratio between the sample of the present temperature and the maximum allowable operating temperature;
• or (2) the difference between the sample of the present temperature and the maximum allowable operating temperature if the sample of the present temperature is less than the maximum operating temperature;
• and
• g) halting charging if the sample of the measured temperature exceeds the maximum operating temperature.