Electrical vehicle charging system for charging an electrical vehicle

Abstract

The application relates to an electrical vehicle charging system for charging an electrical vehicle with a DC current, including a charger, an air conditioning device and a control device, whereby the charger is configured for delivering the DC current to the electrical vehicle, the air conditioning device is configured for heating and/or cooling the charging system, the air conditioning device and/or the charger emits a noise, and the control device is configured for controlling delivery of the DC current according to the noise.

Claims

1. An electrical vehicle charging system for charging an electrical vehicle with a DC current, comprising: a charger, the charger including: an air conditioning device, and a control device; wherein the charger is external to the electrical vehicle and configured for delivering the DC current to the electrical vehicle; wherein the air conditioning device is external to the electrical vehicle and configured for heating and/or cooling the charger; and wherein the air conditioning device and/or the charger emits a noise; wherein the control device is configured to calculate a power level of the air conditioning device based on the noise level and the control device limits a power provided to the air conditioning device based on the calculation and a predefined limit; wherein the control device is external to the electrical vehicle and configured to control a delivery of the DC current output by the charger such that the charger does not overheat and to set a level of DC current provided by the charger to the electric vehicle in response to the noise.

2. The electrical vehicle charging system according to claim 1, wherein the control device is configured for limiting delivery of the DC current such that the noise does not exceed the predefined limit.

3. The electrical vehicle charging system according to claim 1, wherein the air conditioning device and/or the charger comprises a fan emitting the noise and the control device is configured for controlling delivery of the DC current based on a number of revolutions of the fan.

4. The electrical vehicle charging system according to claim 1, wherein the control device is configured for controlling delivery of the DC current according to a predefined time or according to a predefined time until the electrical vehicle has to be charged by a predefined level.

5. The electrical vehicle charging system according to claim 1, wherein the control device is configured for limiting delivery of the DC current such that the noise at the charger does not exceed a first predefined limit during a first time span and the noise at the charger does not exceed a second predefined limit during a second time span; wherein the first time span and the second time span is during a single charging operation and wherein the first time span is different from the second time span.

6. The electrical vehicle charging system according to claim 1, wherein the control device is configured for limiting the noise to ≤40 dB.

7. The electrical vehicle charging system according to claim 1, wherein controlling delivery of the DC current output by the charger comprises reducing a level of the DC current output by the charger from a first DC current level to a second DC current level in response to a temperature of the charger reaching a maximum acceptable temperature; wherein the charger outputs the second DC current to charge the electrical vehicle.

8. The electrical vehicle charging system according to claim 1, further comprising a DC charging cable having a first end and a second end, wherein the first end is connected to the charger for receiving DC voltage and the second end is configured for connecting the electrical vehicle.

9. The electrical vehicle charging system according to claim 1, wherein the charger comprises a power transformer having a first side and a second side and a power converter having an AC side and a DC side, the first side of the power transformer is configured for connecting to an AC grid, the second side of the power transformer is connected to the AC side of the power converter and the DC side of the power converter is configured for providing electrical energy to charge the electrical vehicle.

10. The electrical vehicle charging system according to claim 1, wherein the charger comprises a switchable connection matrix device comprising a number of outlet ports each configured for electrically connecting the electrical vehicle and the switchable connection matrix device is configured for connecting one or a plurality of power converters to each of the number of outlet ports.

11. A method for controlling a noise emission of a charger for an electric vehicle, the charger including an air conditioning device, and a control device, the method comprising: delivering, by the charger, a DC current to charge the electrical vehicle, wherein the charger is external to the electrical vehicle; air conditioning the charger, wherein air conditioning and/or delivering the DC current emits a noise; calculating, by the charger, a power level of the air conditioning device based on the noise level; providing power to the air conditioning device based on the calculation and a predefined limit; controlling a delivery of the DC current such that the charger does not overheat; and controlling a magnitude of the DC current provided by the charger to the electric vehicle based on a detected level of the noise; wherein the air conditioning device and the control device are disposed external to the electrical vehicle.

12. The method according to claim 11, further comprising controlling delivery of the DC current such that the noise does not exceed the predefined limit.

13. The method according to claim 11, wherein air conditioning the charger comprises ventilating the charger and/or comprising an air conditioning device providing the air conditioning and further comprising controlling delivery of the DC current based on a number of revolutions of a fan of the air conditioning device.

14. The method according to claim 11, further controlling delivery of the DC current according to a predefined time or according to a predefined time until the electrical vehicle has to be charged by a predefined level.

15. The method according to claim 11, wherein controlling delivery of the DC current comprises limiting delivery of the DC current such that the noise does not exceed a first predefined limit during a first time span and not exceed a second predefined limit during a second time span.

16. The method according to claim 11, wherein controlling delivery of the DC current comprises limiting the noise to ≤40 dB and/or reducing the DC current until the noise does not exceed the predefined limit.

17. The electrical vehicle charging system according to claim 2, wherein the air conditioning device and/or the charger comprises a fan emitting the noise and the control device is configured for controlling delivery of the DC current based on a number of revolutions of the fan.

18. The electrical vehicle charging system according to claim 2, wherein the control device is configured for controlling delivery of the DC current according to a predefined time or according to a predefined time until the electrical vehicle has to be charged by a predefined level.

19. The electrical vehicle charging system according to claim 2, wherein the control device is configured for limiting delivery of the DC current such that the noise emitted by the charger does not exceed a first predefined limit during a first time span and not exceed a second predefined limit during a second time span.

20. The method according to claim 12, wherein air conditioning the charger comprises ventilating the charger and/or comprising an air conditioning device providing the air conditioning and further comprising controlling delivery of the DC current based on a number of revolutions of a fan of the air conditioning device.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

(2) In the drawings:

(3) FIG. 1 shows an electrical vehicle charging system for charging an electrical vehicle 1 according to a preferred embodiment of the invention in a schematic view.

DESCRIPTION OF EMBODIMENTS

(4) FIG. 1 shows an electrical vehicle charging system for charging an electrical vehicle 1 according to a preferred embodiment of the invention in a schematic view. The charging system comprises a charger 2 configured for delivering a DC current via a DC charging cable 3 to the electrical vehicle 1. Thereby, the DC charging cable 3 is firmly connected with its first end 4 to the charger 2 and with its second end 5 via a connector to the electrical vehicle 1. The connector is provided according to norm IEC 62196.

(5) The charging system comprises a power transformer 6 and a power converter 7. The power transformer 6 is connected with its primary side to an AC grid 8 and with its secondary side to the power converter 7, which converts the received AC power into DC power for delivering the DC current for charging a battery of the electrical vehicle 1. The charger further comprises a switchable connection matrix device 12, which comprises a number of outlet ports 13 each configured for electrically connecting the electrical vehicle 1. The switchable connection matrix device 12 allows for connecting one or a plurality of power converters 7 to the respective outlet port 13.

(6) The charging system further comprises an air conditioning device 9 for heating and/or cooling the charging system. The air conditioning device 9, the charger 2, the power transformer 6 and the power converter 7, in particular during heating, cooling respectively charging, emit a noise characterized by a noise level. The noise originates, among others, by a fan 10 of the air conditioning device 9 required for blowing hot respectively cool air for heating respectively cooling the charging system, or results from magnetostriction of the transformer or the converter.

(7) Operation of the air conditioning device 9 is controlled by a computerized control device 11 such that delivery of the DC current happens according to the noise. Particularly, delivery of the DC current is limited by the control device 11 such that the emitted noise does not exceed a predefined limit of not more than 40 dB, measured at one meter distance to the charging system. Thus, in order not the exceed said limit, the ventilation speed is controlled by the control device 11 and depending on the ventilation speed delivery of the DC current is controlled i.e. increased or decreased. For example, if the control device 11 detects that the noise level is more than 40 dB, the control device 11 reduces ventilation speed and also reduces the level of DC current delivered to the electrical vehicle 1 such that the reduced ventilation speed suffices for cooling the charging system in order to ensure operational stability during charging.

(8) It is possible that the control device 11 controls delivery of the DC current according to a predefined time. For example, the level of DC current can be higher during day time than at night time. Further, controlling the DC current can be depending on reaching a predefined charging level. For example, if the electrical vehicle 1 has to be fully charged by 08:00 am, while charging during 08:00 pm and 08:00 am can only be done at a reduced rate of 50%, then charging may start for example at 06:00 pm with 100% DC current and may continue between 08:00 pm and 08:00 am at 50% DC current.

(9) This said, the control device 11 may control delivery of the DC current such that the noise does not exceed a first predefined limit during a first time span, for example during night times, and not exceed a second predefined limit during a second time span, for example during day times. Thus, the control device 11 controls speed of the fan 10 of the air conditioning device 9 accordingly. Practically, controlling delivery of the DC current means reducing the DC current until the noise does not exceed the predefined limit.

(10) In sum, the charging system allows for various implementations. For example, being implemented as a home charger, a user of the charging system could indicate that between 08:00 pm and 8:00 am the fan 10 should spin at no more than 30% of the maximum ventilation speed, unless the electrical vehicle 1 is not fully charged by 7:30 am. The charger 2 starts charging at reduced power until electrical components of the charging system i.e. the charger 2, the power converter 7 or the power transformer 6 reach a maximum acceptable temperature. If the control device 11 predicts that the electrical vehicle 1 will not be fully charged by 7:30 am unless the ventilation is increased, the control device 11 will increase the ventilation level by the minimum required amount that charging will take to finish charging at 7:30 am.

(11) In a further example, a network operator is allowed to place a charging system in a residential area, but the charging system limited to 40 dB noise between 07:00 pm and 8:00 am. The maximum fan 10 power level can be calculated from this noise level, and the fan 10 power is controlled by the control device 11 to never higher than this setting. If the electronic components reach the maximum acceptable temperature, the output power of the charger 2 is reduced. In this case the user is not able to override the setting, as the permit does not allow this. However, charging is still possible even in noise sensitive environments.

(12) While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. Other variations to be disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting scope.

REFERENCE SIGNS LIST

(13) 1 electrical vehicle

(14) 2 charger

(15) 3 charging cable

(16) 4 first end

(17) 5 second end

(18) 6 power transformer

(19) 7 power converter

(20) 8 AC grid

(21) 9 air conditioning device

(22) 10 fan

(23) 11 control device

(24) 12 switchable connection matrix device

(25) 13 outlet port