Matrix switches for optimizing resource utilization in large-scale charging stations with distributed energy resources
11285831 · 2022-03-29
Assignee
Inventors
- Emil Youssefzadeh (Palos Verdes Estates, CA, US)
- Marcelo Barros (Ladera Ranch, CA, US)
- Salim Youssefzadeh (Redondo Beach, CA, US)
Cpc classification
H02B1/20
ELECTRICITY
Y02T10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02T90/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02T90/14
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60L53/30
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/7072
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B60L53/30
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A DC matrix power switch structure mechanically and electrically connects m DC power modules to n charge dispensers for charging electric vehicles. The matrix includes an input structure having m conducting input busbar pairs and an output structure having n conducting output busbar pairs. A first busbar of n output busbar pairs is connected to a positive voltage terminal and a second busbar of n output busbar pairs is connected to a negative voltage terminal of each of n charge dispensers, producing two times m×n busbar crossing points. A power switch is mechanically mounted to a cross point or is moved to a crossing point and, when activated, connects to the associated busbar at the busbar crossing point providing power to the appropriate charge dispenser. A power switch includes one or more actuators to connect an input busbar to an output busbar with a flexible conductor.
Claims
1. A DC matrix power switch (m×n matrix) that mechanically and electrically connects m DC power modules to n charge dispensers for charging electric vehicles comprising: an input structure having one or more input busbar pairs wherein the one or more input busbars pairs are generally parallel and straight electrical conductors whose cross-section and conductivity are configured for a maximum input current consistent with a DC power module output, and wherein the one or more input busbar pairs are aligned and fixed parallel to each other thereby forming the input structure of parallel busbars; wherein the first busbar of the input busbar pair is associated with a positive voltage and has an attachment mechanism for allowing the connection of the positive voltage terminal of the DC power module and the passage of the maximum output current of the DC power module; wherein the second busbar of the input busbar pair is associated with a negative voltage and has an attachment mechanism for allowing the connection of the negative voltage terminal of the DC power module and the passage of the maximum output current of the DC power module; wherein the current flows from the positive to the negative voltage busbars; wherein an output structure including one or more output busbar pairs wherein the output busbars pairs are electrical conductors whose cross-section and conductivity are designed for a maximum output current consistent with a charge dispenser's maximum current demand, and the one or more output busbar pairs are aligned and fixed parallel to each other thereby forming the output structure of parallel busbars; wherein the first busbar of the output busbar pair is associated with a positive voltage and has an attachment mechanism to allow the connection of the positive voltage terminal of the charge dispenser and the passage of the charge dispenser's maximum current demand; wherein the second busbar of the output busbar pair is associated with a negative voltage and has an attachment mechanism to allow the connection of the negative voltage terminal of the DC power module and the passage of the charge dispenser's maximum current demand; wherein the current flows from the positive to the negative voltage busbars; a power switch comprising one or more actuators to mechanically and electrically connect an input busbar to an output busbar with a flexible conductor configured to carry at least the maximum current of the DC power module; a translation stage assembly for each input busbar pair further comprising: a translation stage; a power switch assembly that positions and secures two power switches to the translation stage such that the power switches can be aligned to the orthogonal input and output busbars near their crossing point, and when the power switches are actuated, the power switches connect the positive voltage input busbar to the positive output busbar of the crossing busbar pairs, wherein when the power switches are not actuated, or power to the power switches is lost, the busbars are not connected; and an alignment structure to support and position the input structure relative to the output structure in a matrix such that the input busbar pairs are orthogonal to the output busbar pairs and to support and attach the translation stage assemblies along with each input busbar pair so that translation movement is parallel to the input busbar pair and traverses a distance that accesses crossing output busbar pairs, thereby allowing the power switch assembly to make connections between input and output busbar pairs.
2. The DC matrix power switch of claim 1 wherein the power to operate the DC matrix power switch, including at least the power to the actuators and translation stages, includes an uninterruptible power supply configured to provide at least enough power to safely shut down the switch in the event of a power interruption.
3. The DC matrix power switch of claim 1 wherein position sensors are used to determine the location of the power switches within the matrix before the connections are made between the selected busbar pairs.
4. The DC matrix power switch of claim 1 wherein a temperature monitoring safety and predictive maintenance system is incorporated to determine the health of the matrix power switch and whether all or parts of the switch should be shut down, scheduled for maintenance or temperature controlled to maintain proper operational characteristics.
5. The DC matrix power switch of claim 1 wherein a vibration monitoring safety and predictive maintenance system is incorporated to determine the health of the matrix power switch and whether all or parts of the switch should be shut down or scheduled for maintenance to maintain proper operational characteristics.
6. The DC matrix power switch of claim 1 wherein the power flow is reversed so that power flows from charge dispensers back towards the DER system.
7. The DC matrix power switch of claim 1, combined in a hybrid configuration where some connections are made using translation stage positioned power switches and other connections are made from fixed power switches located at input/output busbar crossing points.
8. The DC matrix power switch of claim 1, wherein the one or more actuators of the power switch comprise a servo motor that includes a pair of crankshaft actuators that push the flexible conductor to connect an input busbar to an output busbar.
9. The DC matrix power switch of claim 8, wherein the flexible conductor comprises a braided copper strap contact.
10. The DC matrix power switch of claim 9, wherein the braided copper strap contact comprises a spring-loaded mechanism that provides for articulation between a contact position and a non-contact position.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The skilled artisan will understand that the drawings are for illustration purposes only. The drawings are not intended to limit the scope of the present teachings in any way.
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(15) Before one or more embodiments of the present teachings are described in detail, one skilled in the art will appreciate that the present teachings are not limited in their application to the details of construction, the arrangements of components, and the arrangement of steps set forth in the following detailed description or illustrated in the drawings. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting.
DESCRIPTION OF VARIOUS EMBODIMENTS
(16) In
(17) Heavy-duty EVs, such as commercial trucks, require electric charging stations that handle different battery capacities and have sufficient space and energy capacity for multiple charge dispensers to simultaneously connect and charge numerous large EVs. Each charging station may require upwards of 30 charge dispensers of varying power from 250 kW to over 1 MW that can service light, medium, and heavy-duty trucks. The aggregate power requirements in such instances may well exceed 25 MW.
(18) Implementation of such a charging station poses challenges for optimizing the sharing of multiple DER system resources to achieve maximum energy and cost efficiency while minimizing energy curtailment. First, the aggregate converter power is designed for peak time utilization at the charging station but is incrementally expandable to meet demand while maintaining the shortest average charge session.
(19) Referring to
(20) Solar array 115 supplements power from a utility's electrical grid 102. Solar array 115 includes a plurality of individual solar panels 115a, 115b, and up to a large number of solar panels 115n. Output power from solar array 115 interfaces with other energy resources of the DER system via the voltage conditioning-switching-distribution subsystem 116. The output of the voltage conditioning-switching-distribution subsystem 116 ultimately feeds the DC power modules 118a to 118m or provides local power to run the charging station and support facilities. Similarly, other power sources such as wind turbines 117, emergency generators (not shown), and hydro-generators 119 are connected to the voltage conditioning-switching-distribution subsystem 116 and supplement power from power grid 102. Power generated in excess of the immediate needs can be stored in the battery energy storage systems (BESS) 121 and retrieved later when needed to supplement demand. BESS 121 can be large industrial battery packs 121a, 121b to 121n composed of Li-Ion batteries, or batteries with similar capabilities, stored in special facilities. Other BESS 121 configurations can include fleet vehicles (e.g., school buses) parked when not being used or EVs parked while drivers are staying the night or resting in their vehicles.
(21) Referring to
(22) In
(23) Referring
(24) Referring to
(25) Note that a third embodiment (not shown) can be a hybrid design combining some assemblies moved by a translation stage, as in the first embodiment, and some assemblies mounted to the frame, as in the second embodiment, as required to optimize the design.
(26) It may be further noted that a fourth embodiment (not shown) is an m×n DC matrix power switch that connects m DC power modules to n charge dispensers for charging electric vehicles comprising an input structure having m conducting input busbar pairs, wherein a first busbar of each of m input busbar pairs is connected to a positive voltage terminal of each of said m DC power modules, wherein the second busbar of m input busbar pairs is connected to a negative voltage terminal of each of said m DC power modules, an output structure having n conducting output busbar pairs, wherein a first busbar of each of said n output busbar pairs is connected to a positive voltage terminal of each of said n charge dispensers, wherein a second busbar of each of said n output busbar pairs is connected to a negative voltage terminal of each of said n charge dispensers, wherein said input structure and said output structure are arranged to form an m by n crossing busbar pairs corresponding to two times m by n busbar crossing points, a dual-axis translation stage assembly that interfaces with each of said m by n busbar pair crossing points, wherein said m power switch assemblies comprises of two power switches, wherein each said power switch assembly can be individually positioned and attached to said matrix power switch structure and released by said dual-axis translation stage assembly at each of said m by n busbar pair crossing points, wherein when released by said dual-axis translation stage, said power switch assembly remains attached to said matrix power switch structure and wherein said dual-axis translation stage becomes available to grab a next power switch assembly for positioning, wherein said dual-axis translation stage assembly can remove an attached power switch assembly and reposition said assembly to another busbar crossing point or park said assembly in an inactive position, a communication link to send commands to activate or deactivate each of said attached power switch assembly, wherein when activated, said power switch assembly connects to its associated busbar pairs at said busbar pair crossing points, wherein connections are made between said busbar pairs such that current flows from positive to negative when said DC power modules are active and the said dispensers are charging a vehicle, and when power is removed from said power switch, or when said power switch receives a command to deactivate, said connection between said associated input and said output busbars is terminated.
(27) Referring still to
(28) In all preferred embodiments of the present invention, each power switch 144a, 144b of
(29) Each power switch 144a, 144b of
(30) Dual-polarity input busbars 143a to 143m are structurally supported by corresponding non-conductive brackets 158 as shown in
(31) In the first embodiment and referring to
(32) For both embodiments, once power switch 145 is enabled, it can only change state once the respective DC power module is in the idle or off state 172. Power switches are not to be connected or disconnected when busbars are hot.
(33) The centralized management system 124 of
(34) Referring to
(35) Centralized management system 124 controls circuit breakers 176a, 176m of
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(41) MPS 120 disclosed herein achieves cost savings by lowering the requirements of some electrical components when certain operational assumptions are true, such as establishing electrical contact exclusively under idle/off-load conditions.
(42) MPS 120 disclosed herein includes an uninterruptable power supply (UPS) to allow its safe operation and shutdown in the event of a power interruption. In addition, the MPS is critical to operating the charge dispenser systems and has electromechanical parts that will need maintenance for continued safe operation. Therefore, the system may incorporate predictive maintenance software and sensors to identify and predict failures so maintenance can be scheduled and downtime can be minimized or avoided. Sensors that measure and locate temperature and vibration anomalies are expected to be installed. Examples of such systems are thermal imagers, discrete temperature sensors systems, and discrete and arrays of vibration sensors combined with vibration analysis software.
(43) The following descriptions of various implementations of the present teachings have been presented for purposes of illustration and description. It is not exhaustive and does not limit the present teachings to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practicing the present teachings. Additionally, the described implementation includes software, but the present teachings may be implemented as a combination of hardware and software or in hardware alone. The present teachings may be implemented with both object-oriented and non-object-oriented programming systems.
(44) While the present teachings are described in conjunction with various embodiments, it is not intended that the present teachings be limited to such embodiments. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art.
(45) Further, in describing various embodiments, the specification may have presented a method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the various embodiments.