System and Method for Sequential Power Charging Switching for Electric Vehicle(s)
20220410757 · 2022-12-29
Inventors
Cpc classification
B60L53/67
PERFORMING OPERATIONS; TRANSPORTING
B60L53/11
PERFORMING OPERATIONS; TRANSPORTING
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
B60L53/63
PERFORMING OPERATIONS; TRANSPORTING
B60L53/31
PERFORMING OPERATIONS; TRANSPORTING
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
B60L53/68
PERFORMING OPERATIONS; TRANSPORTING
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
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
B60L53/67
PERFORMING OPERATIONS; TRANSPORTING
B60L53/10
PERFORMING OPERATIONS; TRANSPORTING
B60L53/30
PERFORMING OPERATIONS; TRANSPORTING
B60L53/31
PERFORMING OPERATIONS; TRANSPORTING
B60L53/63
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A multi-charger, serially operated electrical vehicle (EV) charging system, contains a Power Control System (PCS) providing DC power. A plurality of EV chargers is serially power-connected to each other, wherein the first EV charger is connected to the PCS. There are sets of relays in at least the first EV charger, wherein a first set of the set of relays, when activated, is configured to supply power to a respective charging cable of the EV charger, and a second set of the set of relays, when activated, is configured to supply power to a next-serially connected EV charger. The sets of relays contain auxiliary contacts providing relay status information. A hardware logic prevents the first and second sets of relays from simultaneously being activated, allowing only one EV charger of the plurality of EV chargers to charge at a time.
Claims
1. A multi-charger, serially operated electrical vehicle (EV) charging system, comprising: a Power Control System (PCS) providing DC power to an output line; a plurality of EV chargers serially power-connected to each other; and a first EV charger of the plurality of EV chargers connected to the DC output line, sets of relays in at least the first EV charger, connected to the DC output line, wherein a first set of the set of relays, when activated, is configured to supply power to a respective charging cable of the EV charger, and a second set of the set of relays, when activated, is configured to supply power to a next-serially connected EV charger, wherein the sets of relays contain auxiliary contacts providing relay status information; and a controller, preventing the first and second sets of relays from simultaneously being activated, allowing only one EV charger of the plurality of EV chargers to charge at a time.
2. The system of claim 1, further comprising an AC Power Inverter providing DC power to the PCS.
3. The system of claim 2, wherein the AC Power Inverter and PCS are an integrated, single system.
4. The system of claim 1, wherein a last of the serially connected plurality of EV chargers does not contain multiple sets of relays.
5. The system of claim 1, wherein an activated first set of relays is a Take condition, enabling a charging operation.
6. The system of claim 1, wherein an activated second set of relays is a Pass condition, enabling a pass of power operation.
7. The system of claim 1, further comprising an EV charger communication channel, between EV chargers.
8. The system of claim 8, wherein the communication channel communicates to at least one of the PCS and to an external server.
9. The system of claim 9, wherein the communication channel is wireless.
10. The system of claim 1, wherein the controller is hardware circuitry within the EV chargers.
11. The system of claim 1, further comprising a switching logic controlling the EV chargers' sets of relays.
12. The system of claim 11, wherein the switching logic is software-based and hosted on an external server communicating with the PCS.
13. The system of claim 12, wherein the switching logic utilizes a Time-Based Round Robin (TBRR) approach.
14. The system of claim 13, wherein the switching logic further utilizes at least one of Set Point threshold, State of Charge threshold, Charged Time, User action, EV Fault, and number of EVs charging to determine an operation duration for an EV charger of the plurality of EV chargers.
15. The system of claim 1, wherein the first and second sets of relays are first and second pairs of relays, and one side of the pairs of relays is connected to a DC positive and another side of the pairs of relays is connected to a DC negative or ground.
16. A method of charging a plurality of EVs in a multi-EV charging station, comprising: connecting a first EV charger of a plurality of EV chargers to a DC output line of a Power Control System (PCS); connecting a DC power line of each next EV charger of the plurality of EV chargers to each other to form a serial power connection between EV chargers, including the first EV charger; establishing a communication channel between each EV charger of the plurality of EV chargers and also to the PCS; and operating only one EV charger at a time, wherein each EV charger has at least one of a hardware logic and relay circuitry that physically prevents more than one EV charger activation at a time.
17. The method of claim 16, wherein the operating is controlled via sets of relays having auxiliary contacts in the EV chargers, the auxiliary contacts providing a relay state status to at least one of the hardware logic and a controller, via the communication channel.
18. The method of claim 16, wherein the operating utilizes a Time-Based Round Robin (TBRR) approach.
19. The method of claim 18, wherein the TBRR approach further utilizes at least one of Set Point threshold, State of Charge threshold, Charged Time, User action, EV Fault, and number of EVs charging to determine an EV charger operation duration.
20. The method of claim 19, wherein the TBRR approach is software based and controlled by an external server in communication to the PCS.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0028] The present disclosure describes exemplary systems and methods that increase charger utilization leading to reduced EV charging infrastructure costs. For example, one or more approaches are presented that increase utilization of a single high-power inverter/Power Control Systems (PCS) by allowing sequential connections. Further, the overall system design can be scalable, enabling the adding of power dispensers in a “series” configuration to a single PCS without the need or additional cost to redesign and re-certify a “centralized” or “hub” switching solution that has a fixed number of connections. The exemplary approach can add more units in the field without replacing or changing a central hub box, which can be costly. In some embodiments, the electrical design is of a “daisy chain” configuration vs. a “hub and spoke” configuration, wherein less cabling is necessary than in conventional approaches.
[0029] Because sequential (or time interleaving) charging is performed, for safety concerns, the exemplary approach can utilize power relay auxiliary contacts+supporting analog circuit(s) to prevent charging to more than one vehicle at a time. This analog circuit design approach removes reliance on software/controls to prevent unsafe sequential connection risks. These and other aspects of the exemplary systems and methods are presented in the following FIGS. descriptions.
[0030]
[0031]
[0032] It is apparent that because the exemplary approach facilitates “only one dispenser charging at a time,” it obviates the need for a separate power distribution cabinet 110, as seen in the prior art of
[0033] As stated above, for safety purposes, only one pair of power relays within a given dispenser can be activated at a time and further, analog circuit protection can be used within the dispensers. Specifically, by utilizing auxiliary relay contacts connected to the power relays and preventing both pairs of power relays from closing at the same time, uncontrolled current flow from one vehicle to another vehicle can be prevented. This fault condition could result in possible damage to equipment or vehicle and other safety concerns. Avoiding this is accomplished by detecting the state of auxiliary relay(s) and acting accordingly.
[0034] Note: These auxiliary contacts may be looked at as small signal level relays that are physically connected to the main power relay and physically move/switch along with the main power relay. This feature is typically used to monitor relay state (e.g., open or closed) at a low voltage/signal level. It can also be used to detect whether a given relay is stuck open or closed.
[0035] In an exemplary configuration, the power relays are configured as “normally open” (No current flow when the coil is not energized). The auxiliary (relay) contacts on these power relays offer both “normally open” and “normally closed” signal connections. The auxiliary contacts on one pair of power relays can be used to either allow or prevent closing the other pair of power relays. This analog approach is a safety design that does not depend on software controls alone to prevent both sets of power relays closing at the same time. Therefore, this approach provides near fool-proof safety interlocking of the relays' contactors.
[0036] It is also understood that in some embodiments, an AC-DC power inverter may not be necessary as a front end to the exemplary system, so as to only require a PCS. This would arise if the originating power source is a DC power source. Or, the power inverter is integrated into the PCS.
[0037]
[0038]
[0039] Here, it is understood that 4 power relays (set up in +/−pairs) are in each Dispenser (except, optionally, for the last series connected dispenser 404, discussed below). In “each” dispenser, one pair of power relays controls power to the EV charging connector and represents a “Take” power condition when “On” and a “non-power Take” condition when “Off.” The other pair of power relays within the dispenser controls power to the next connected dispenser and represents a “Pass” power condition when “On” and a non-power Pass condition when “Off.”
[0040] Since the last Dispenser 404 is not serially connected to a follow-along dispenser, it can be defaulted automatically to a Take condition and therefore, the “Pass” set of power relays are not used. If there is no desire to add a follow-along dispenser to the last Dispenser 404, then Dispenser 404 can be a conventional dispenser type, not having the 4-relay configuration described above, understanding that it will not be able to supply power to a later added dispenser.
[0041] 410 represents a possible “Standby” default scenario where no EV is being charged. All but the last Dispenser 404 is in an “Off” Pass & Take state. No power is fed into any of the Dispensers.
[0042] 420 represents a possible “Dispenser 1 charging” scenario where an EV is being charged by the first Dispenser 401. Here, first Dispenser 401's Take condition is “On” and the attendant power relays are engaged so power can be being fed into first Dispenser 401's EV charging cable/connector. Not shown, but evident is the Pass condition-set here as “Off”, so that the attendant power relays for passing power to the next dispenser are not engaged, preventing power from being forwarded to the next connected dispenser(s). Therefore, the next connected dispensers 402, 403 can have their Take and Pass power relays in an Off state.
[0043] 430 represents a possible “Dispenser 2 charging” scenario where an EV is being charged by the second Dispenser 402. Since no power is being “used” by the first Dispenser 401, its power relays for Take are not engaged (or set to off) and the power relays for Pass are engaged (or set to on), forwarding power to second Dispenser 402. Since the second Dispenser 402 is providing power to a connected EV, its Take condition is “On” and the attendant power relays are engaged to supply power to its charging cable/connector. The next-connected third Dispenser 403, not being active, has its Take and Pass relays in an Off state.
[0044] It should be apparent from the above that if a Dispenser is positioned later in a line of Dispensers, and if that later Dispenser is the Dispenser charging an EV, then the prior Dispensers' Take and Pass relays can be appropriately toggled to Pass power as needed.
[0045] Scenarios 440 and 450 represent the next sequence of conditions-third Dispenser 403 charging an EV and the fourth Dispenser 404 charging an EV, respectively. In view of the explanations provided for scenarios 420 and 430 above, and the descriptions in
[0046]
[0047] Since the Take and Pass relay pairs share a common positive connection and common negative connection, supply power to the Dispenser relay board 555 can be sent to either the Take relay or Pass relay connections. That is, the positive line from the PCS or prior Dispenser can be connected to either one of the positive Take or Pass relays via the appropriate terminal connections; and the negative line from the PCS or prior Dispenser can be connected to either one of the negative Take or Pass relays via the appropriate terminal connections. It should be expressly understood that the term negative (in the context of a DC circuit) is also considered the ground, and the terms may be used interchangeably.
[0048]
[0049] Terminals 617 and 627 are the Pass terminals and are connected to relays Y and Z. A follow-on or subsequently connected dispenser is connected to these terminals 617, 627 (+/− or =/+). Relays W and X have connections (not shown) that supply+/− or =/+) power to the Dispenser's charging cable/connector.
[0050] It should be understood that the W-, X-to-Pass and Y-, Z-to-Take matching shown above are conventions for explanation and do not necessarily signify these “labeled” relays are hard fixed to their respective functions. For example, it is possible for the W, X relays (if appropriately placed) to be designated for the Take function while the Y, Z relays (if appropriately placed) are designated for the Pass function. Therefore, the W, X, Y, Z assignments may vary depending on either the context, implementation preference or circuitry shown.
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[0057] As an example, to achieve the W, X, Y, Z states (0,0,1,1) shown in row 3 of
[0058] In some embodiments, the logic “controlling” circuitry may be wholly within the charger, or wholly/partially within the PCS. In other embodiments, it may be external to both.
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[0061] (a) Charging Order by Dispenser 1.fwdarw.2.fwdarw.3.fwdarw.4.fwdarw.5
[0062] (b) Because the system can be intelligently controlled, it can alternately perform management of sequential charging based on order of parking (charging) spots.
[0063] (c) In some embodiments, the PCS 1210 can be rated for a lower power (e.g., 60 kW) or higher power (e.g., 125 kW) and deliver power accordingly. Other “scheduling” schemes are further detailed below.
[0064]
[0065] Buses 1, 3 and 5 plugged in: [0066] a. Charging will start with Dispenser 1 [0067] b. Skip Dispenser 2 since there is no bus [0068] c. Dispenser 3 will charge to scheduled State of Charge (SOC) [0069] d. Skip dispenser 4 since there is no bus [0070] e. Dispenser 5 will charge to SoC [0071] f. 1.fwdarw.2(skip).fwdarw.3.fwdarw.4(skip).fwdarw.5
[0072]
Example: Displ=>90%; Disp 2=>80%; Disp 3=>70%; Disp
[0073] 4=>65%; Disp 5=>100%. Of course, these values are for demonstration and other values may be used according to design preference.
[0074] Also, the driver can stop charging at dispenser by pushing a stop charge button on the dispenser or an administrator can remotely send a stop command from a cloud platform.” Trying to indicate there are many ways to stop the charge session to move to the next dispenser. The above process can be implemented in software either in the PCS and/or in a server connected to the exemplary system.
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[0083] Of course, the above conditions are not the only conditions useable and are offered to demonstrate one set of many possible conditions. Therefore, an operator or manager of a charging system may determine other parameters and values for determining a Pass, etc. condition. For example, the operator may decide that after 5 minutes of the PCS being off, the next dispenser will ‘Take’ and start charging, or a Set Point is 90% of max power, etc. This process can be implemented in software either in the PCS and/or in a server connected to the exemplary system.
[0084] Using a TBRR approach, the exemplary process 1500 shown in
[0085] If 1530's test determines power is flowing, the process 1500 concludes that charging is occurring and performs a series of “charging condition” tests (1550) for switching to another charger in the system (e.g., when to round robin). The first test 1555 is see if the Power is below a predetermined Set Point threshold (shown here, for example, below 10 kW). If insufficient power is being used (Y), the process 1500 shuttles to a Shut condition 1580, understanding that very little charging is occurring, and turns the charging off to allow a Pass condition 1580 to the next (not shown) charger/vehicle. Upon a Pass condition 1580, the process restarts at step 1510.
[0086] If test 1555 determines sufficient power is flowing, test 1560 checks to see if SOC above a predetermined threshold (shown here, for example, above 85%). If Yes, then the process 1500 proceeds to the Shut condition 1580 to allow Pass condition 1580 to the next (not shown) charger/vehicle.
[0087] If test 1560 is No, then a time of charging test 1565 is performed, the example here being 1 hr. If charging has been for more than an hour, the process 1500 goes to the Shut 1580 and Pass 1590 conditions. If not, the next test 1570 is performed, to see if the user has stopped the charging. If yes, then process 1500 goes to the Shut 1580 and Pass 1590 conditions. If not, then the process 1500 returns to step 1515 and the restarts from there.
[0088] It should be understood that while the above process steps, algorithms or the like may be described in a sequential order, such processes may be configured to work in different orders. In other words, any sequence or order of steps that may be explicitly described does not necessarily indicate a requirement that the steps be performed in that order. For example, the unit charging steps 1550 may be in different order, or less or additional steps may be implemented. Further, some steps may be performed simultaneously despite being described or implied as occurring non-simultaneously (e.g., because one step is described after the other step). Moreover, the illustration of a process by its depiction in a drawing does not imply that the illustrated process is exclusive of other variations and modifications thereto, does not imply that the illustrated process or any of its steps are necessary to the invention, and does not imply that the illustrated process is preferred.
[0089] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims.