Intermittent problems with iphone 3g "charging not supported"

I notice quite a few complaints about intermittent 'charging not supported' messages.
I have been getting the same message on my iphone 3g.
I have ELIMINATED the cord and plug as the problem in this case by the following method:
I found that by LOWERING the line voltage to the charger with a variac, I could get rid of the message RELIABLY for a period of time.
By turning the variac off and on, and by varing the voltage setting, I can reproduceably get either charging or 'charging not supported'.
Since there are no changes being made in the connections to the phone and charger, I eliminate them as causing to the problem.
I suspect a deteriorating component in the charger is reporting some kind of error to the phone via some communications channel.
I have not tried opening the charger, but if and when it finally dies, I will do so.
This morning, the charger worked with the variac set to 80 volts.
Anyone on the design team around that can suggest other tests?
-bz-

The unit finally failed and I opened it up. It appears to consist of an AC-->dc converter with suitable filters and regulators and a small computer that probably talks via I2C or a similar protocol to the iphone.
I suspect that components are defective and the output voltage is outside the range it thinks it should be or some problems with the communications cause it to send an erronious message in response to the query sent by the iphone. I did NOT see any obviously bulging electrolytic capacitors, but I did not test for high ESR and I suspect that is the problem.
A 'off brand' AC Charger of iPod and iPhone from Radio Shack works fine while BOTH authentic APPLE iphone 'tiny cube' chargers are going for recycling.
Software fixes may cause the iphone to either keep trying until it gets the right response or ignore the erronious responses.

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