Digital Power Multiport Battery Charging System
20180123360 ยท 2018-05-03
Assignee
Inventors
Cpc classification
B60L53/31
PERFORMING OPERATIONS; TRANSPORTING
B60L58/12
PERFORMING OPERATIONS; TRANSPORTING
Y04S20/222
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
Y02E60/00
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
Y04S10/126
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
Y02T10/70
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
H02J7/0013
ELECTRICITY
Y02B70/3225
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
H02J2310/60
ELECTRICITY
H02J7/00712
ELECTRICITY
Y02T90/16
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
H02J7/007188
ELECTRICITY
Y02B90/20
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
H02J2310/64
ELECTRICITY
B60L53/62
PERFORMING OPERATIONS; TRANSPORTING
B60L58/16
PERFORMING OPERATIONS; TRANSPORTING
H02J7/00034
ELECTRICITY
B60L53/20
PERFORMING OPERATIONS; TRANSPORTING
H02J3/14
ELECTRICITY
B60L53/66
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
H02H5/12
ELECTRICITY
Y02T90/167
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
Y04S30/14
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
Y04S40/124
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
Abstract
The disclosed charging system has multiple charging ports emanating from a central digital power transmitter to charge a plurality of battery packs. The system comprises a centralized bulk power converter to produce a first DC voltage and multiple additive power converters. One additive power converter is assigned to each charger port. The output of each charging port is transmitted in digital power format to a receiver local to each battery pack. The receiver converts the digital power to conventional analog DC power for charging the battery packs. The bulk converter provides the majority of the power needed to charge all the battery packs simultaneously, while the additive power converters adjust for the individual characteristics of each battery pack.
Claims
1. A multiport charging system, comprising; a plurality of charging ports, each configured for coupling to a respective battery pack; a centralized bulk converter electrically coupled with the charging ports and controllable to provide a first output voltage selected to provide a majority of a total charge power required for recharging all battery packs attached to the charging ports; a plurality of additive power converters, wherein each additive power converter is assigned to an individual charging port and is controllable to provide a second output voltage that, when added to the first output voltage, results in a predetermined charge to the charging port to which it is assigned; and a control circuit configured to monitor at least the electrical current leaving the charging ports to control at least the second output voltage of the additive power converters to individually control a charging current to the battery packs attached to the charging ports based on an algorithm that optimizes at least one factor selected from customer satisfaction, price of electricity, maximizing charge rate, available capacity from a power source, and battery life.
2. The multiport charging system of claim 1, wherein the additive power converters are placed local to the bulk converter.
3. The multiport charging system of claim 1, wherein the additive power converters are placed local to the battery pack being charged.
4. The multiport charging system of claim 1, wherein at least one of the additive power converters is an existing onboard charger of an electric vehicle.
5. The multiport charging system of claim 1, wherein the bulk converter is embedded in a digital power transmitter configured to transmit power in digital power format to multiple remote digital power receivers local to the charging ports, and wherein the digital power receivers are configured to convert digital power back to conventional analog power for charging battery packs attached to the charging ports.
6. A method for charging a plurality of battery packs, the method comprising: controlling a centralized bulk converter to provide a first output voltage through a plurality of charging ports to respective battery packs coupled with the charging ports, wherein the first output voltage is selected to provide a majority of a total charge power required for recharging all battery packs attached to the charging ports; controlling a plurality of additive power converters, each assigned to an individual charging port, to provide a second output voltage that, when added to the first output voltage, results in a predetermined charge to the charging port to which it is assigned; and operating a control circuit to monitor at least the electrical current leaving the charging ports to control at least the second output voltage of the additive power converters to individually control a charging current to the battery packs attached to the charging ports based on an algorithm that optimizes at least one factor selected from the following factors: customer satisfaction, price of electricity, maximizing charge rate, available capacity from a power source and battery life.
7. The method of claim 6, wherein the control circuit generates a signal that offers an option for a lower price per unit of energy in exchange for a longer charging period to an owner of at least one of the battery packs.
8. The method of claim 6, wherein the control circuit executes an algorithm that is at least in part determined by information stored in control circuitry in at least one of the battery packs.
9. The method of claim 6, further comprising adjusting the first output voltage to a reduced voltage necessary to accommodate the lowest-voltage battery pack attached to the system, and adjusting the bulk converter voltage upwards as the lowest-voltage battery pack charges.
10. The method of claim 9, wherein the control circuit acts to adjust the first output voltage downward to accommodate a battery pack at a low charge state wherein, because batteries at a low state-of-charge have voltage characteristics that rise rapidly during a first portion of the charge process, any loss or reduction in charging rate to higher charge-state battery packs due to a reduced voltage from the bulk converter will be temporary.
11. The method of claim 6, further comprising using the additive power converters to produce a negative voltage in relation to the bulk converter, wherein adding the output voltage of the bulk converter and output voltage of the additive power converter results in a combined voltage that is less than that of the bulk converter.
12. The method of claim 6, wherein at least one of the additive power converters is an existing onboard charger of an electric vehicle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0043] In the accompanying drawings, like reference characters refer to the same or similar parts throughout the different views; and apostrophes are used to differentiate multiple instances of the same or similar items sharing the same reference numeral. The drawings are not necessarily to scale; instead, an emphasis is placed upon illustrating particular principles in the exemplifications discussed below.
DETAILED DESCRIPTION
[0044] The foregoing and other features and advantages of various aspects of the invention(s) will be apparent from the following, more-particular description of various concepts and specific embodiments within the broader bounds of the invention(s). Various aspects of the subject matter introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the subject matter is not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.
[0045] Unless otherwise herein defined, used or characterized, terms that are used herein (including technical and scientific terms) are to be interpreted as having a meaning that is consistent with their accepted meaning in the context of the relevant art and are not to be interpreted in an idealized or overly formal sense unless expressly so defined herein. For example, if a particular composition is referenced, the composition may be substantially (though not perfectly) pure, as practical and imperfect realities may apply; e.g., the potential presence of at least trace impurities (e.g., at less than 1 or 2%) can be understood as being within the scope of the description. Likewise, if a particular shape is referenced, the shape is intended to include imperfect variations from ideal shapes, e.g., due to manufacturing tolerances. Percentages or concentrations expressed herein can be in terms of weight or volume. Processes, procedures and phenomena described below can occur at ambient pressure (e.g., about 50-120 kPafor example, about 90-110 kPa) and temperature (e.g., ?20 to 50? C.for example, about 10-35? C.) unless otherwise specified.
[0046] Although the terms, first, second, third, etc., may be used herein to describe various elements, these elements are not to be limited by these terms. These terms are simply used to distinguish one element from another. Thus, a first element, discussed below, could be termed a second element without departing from the teachings of the exemplary embodiments.
[0047] Spatially relative terms, such as above, below, left, right, in front, behind, and the like, may be used herein for ease of description to describe the relationship of one element to another element, as illustrated in the figures. It will be understood that the spatially relative terms, as well as the illustrated configurations, are intended to encompass different orientations of the apparatus in use or operation in addition to the orientations described herein and depicted in the figures. For example, if the apparatus in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the exemplary term, above, may encompass both an orientation of above and below. The apparatus may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0048] Further still, in this disclosure, when an element is referred to as being on, connected to, coupled to, in contact with, etc., another element, it may be directly on, connected to, coupled to, or in contact with the other element or intervening elements may be present unless otherwise specified.
[0049] The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting of exemplary embodiments. As used herein, singular forms, such as a and an, are intended to include the plural forms as well, unless the context indicates otherwise. Additionally, the terms, includes, including, comprises and comprising, specify the presence of the stated elements or steps but do not preclude the presence or addition of one or more other elements or steps.
[0050] Additionally, the various components identified herein can be provided in an assembled and finished form; or some or all of the components can be packaged together and marketed as a kit with instructions (e.g., in written, video or audio form) for assembly and/or modification by a customer to produce a finished product.
[0051] Disclosed herein is a unique combination of power conditioning circuitry, digital power receivers and a digital power transmitter that can improve or optimize factors of safety, efficiency, resiliency, control and routing of power, and that can prioritize digital power delivery across multiple loads based on a predetermined priority scheme. In systems described herein, digital power components are configured for the purposes of charging one or more battery packs from a central transmitter.
[0052] The digital power transmitter can be supplied with AC grid power. Within the transmitter, a bulk AC-DC power converter converts the AC power to DC. The DC power has a minimum voltage that is sufficient to charge battery packs that are at a predetermined minimum state of charge. For battery packs below the minimum state of charge, a separate method is employed, as will be described later in this specification. The transmitter also contains an additive power converter for each of the charging ports. The additive power converter can be local to the bulk converter (wherein the distance between the additive power converter and the bulk power converter is less than 25% of the total distance between the bulk power converter and the charging port or battery pack) or the additive power converter can be local to the battery pack being charged (wherein the distance between the additive power converter and the charging port or battery pack is less than 25% of the total distance between the bulk power converter and the battery pack or charging port).
[0053] The additive power converter output voltage and/or current is adjustable from the transmitter controller. The voltage of the additive power converter is added to the bulk power converter voltage. The resulting summed voltage is managed by the transmitter controller to maintain a predetermined charge rate for the battery pack with which the charger port is associated. Before leaving the transmitter, the power on the charger port is converted to digital power format for the purposes of safe distribution to the digital power receiver local to the battery pack/charging port (wherein the distance between the digital power receiver and the battery pack/charging port is less than 25% of the total distance between the digital power transmitter and the battery pack/charging port).
[0054] A receiver associated with each charging port receives the digital power and converts it back to conventional analog DC power to charge the battery pack. Data communication between the battery pack and the receiver and receiver and transmitter allow the intelligent management of the distribution of power from the transmitter to the individual charger ports. The distribution of power may also be based on algorithms that take into account service levels to subscribers of the charging system. For example, a premium subscriber may be provided with a faster charge versus basic subscribers.
[0055] A block diagram of the system is provided in
[0056] A concept relevant to the operation of this system is the voltage versus state-of-charge relationship in typical battery packs. A representative voltage/charge-state profile is depicted in
[0057]
[0058] The relevance of
[0059] The ratings of the additive power converters only need to be a fraction of (i.e., is less than) the rating of the bulk converter according to the relative voltage ratio. For example, if the bulk converter is rated to 30 kW at 320 VDC, and the additive power converter can generate a maximum of 60 VDC (allowing a total charger output of 380 VDC), the additive power converter would require a power rating that is only a fraction of the 30 kW converter according to the ratio of 30 kW*60V/320V=5.6 kW. This would provide a combined charge capability of 35.6 kW. More specifically, according to the example depicted in
[0060] A representative digital power transmitter 1 is shown in
[0061] A representative power control element 14 is shown in
[0062] Referring to the power control element 14 of
[0063] Referring to
[0064] Element control circuitry 20 manages a disconnect device (S1) 24, that is needed to convert the Vb+Va output to digital power format by executing the packet energy transfer (PET) protocol described in detail in Eaves 2012. Disconnect device (S1) 24 can be a power semiconductor device but may also take other forms, such as an electromechanical relay. Voltage sensing point 26 is used to provide feedback voltage when executing PET protocol.
[0065] Referring to
[0066] An instance of a receiver circuit 36 is shown in
[0067] Switch (S2) 42 of
[0068] Referring to the receiver 2 of
Optimization of these factors can include accessing information on the battery pack being charged, such as the battery pack's state-of-charge, capacity, age, and/or temperature. The data may be available from the battery pack control system through an industry standard wired or wireless communication interface symbolized by line 39 of
[0072] Specifically, the system can be configured to allow custodians of the charger system to implement custom algorithms to achieve the above factors. Of note is that customers may choose to trade off the balance of charging time and cost; for example, if the customer has more time available to charge, then he/she may choose to select a lower charging rate if it is offered at a lower price. In another example, since battery life is reduced at higher temperatures caused by fast charging, the urgency of fast charging may be traded off with the financial impact of reduced battery life when optimizing customer satisfaction. In one implementation, depicted in
[0073] The battery pack control system may also communicate a specific charge algorithm to the local charge point that executes a charge profile deemed appropriate by the battery pack or vehicle manufacturer. The battery pack 3 or vehicle 4 can also communicate just an identification number for the charge algorithm to be retrieved from a remote computer server over a public or private computer network.
[0074] Similarly, the optimization of overall charging times for customers may best be served by allocating more charging capacity to a battery pack 3 that is at a very low state of charge that is less than that of others attached to the charging system. Specifically, the bulk converter 12 of
RAMIFICATIONS
[0075] Although the digital power transmitter 1 of
[0076] In
[0077] Thus far, additive power converters 30 have been depicted as producing a positive voltage output in relation to the voltage output of the bulk converter 12. In practice, an additive power converter 30 can instead be used in these embodiments so as to produce a voltage that is negative in relation to the voltage of the bulk converter 12 such that the algebraic sum of the voltage of the bulk and additive power converter 12 and 30 is less than the voltage of the bulk converter 12 alone.
[0078] Many electric vehicles contain an onboard charger unit that is traditionally designed for connection to an AC mains receptacle that may be found in public areas or in a residence. The onboard charger is typically designed with a universal mains input capability to accept a wide range of AC voltages and frequencies (e.g., 100-250 VAC and 50-60 Hz). A universal mains charger will typically also acceptand operate efficiently witha DC input voltage that is sourced from the bulk power converter described in the present invention, thereby allowing the onboard charger to be used as an alternative form of the additive power converter. Referring to
[0079] The instances of the digital power receiver 2, 2, 2, 2 are somewhat simplified in this specification. In practice, the receiver control circuit 40 can be used for additional functions, such as servicing an operator display for control and financing functions, such as interacting with the user to process payment authorization and to offer options on the level of service provided. The receiver control circuit 40, particularly when the additive power converter 30 is local to the receiver 2, can perform local control of the additive power converter 30 to control the charge profile to the battery pack 3 to which it is attached.
[0080] The bulk power converter 12 of
[0081] As earlier described in the specifications of Eaves 2012, the Eaves Receiver Patent, and Lowe 2014, at times the flow of energy in the system can reverse, where power is extracted from a battery pack and distributed to another battery pack, to the grid, or to an energy storage device. In the cases of distributing back to the grid, such a process is known to the industry as vehicle-to-grid operation.
[0082] In one instance, depicted in
[0083] The communications signal 19 of
[0084] Another option for implementing communication using the modulator/demodulator circuit 28 (in
[0085] In describing embodiments of the invention, specific terminology is used for the sake of clarity. For the purpose of description, specific terms are intended to at least include technical and functional equivalents that operate in a similar manner to accomplish a similar result. Additionally, in some instances where a particular embodiment of the invention includes a plurality of system elements or method steps, those elements or steps may be replaced with a single element or step; likewise, a single element or step may be replaced with a plurality of elements or steps that serve the same purpose. Further, where parameters for various properties or other values are specified herein for embodiments of the invention, those parameters or values can be adjusted up or down by 1/100th, 1/50th, 1/20th, 1/10th, ?th, ?rd, ?, ?rd, ?th, ?th, 9/10th, 19/20th, 49/50th, 99/100th, etc. (or up by a factor of 1, 2, 3, 4, 5, 6, 8, 10, 20, 50, 100, etc.), or by rounded-off approximations thereof, unless otherwise specified. Moreover, while this invention has been shown and described with references to particular embodiments thereof, those skilled in the art will understand that various substitutions and alterations in form and details may be made therein without departing from the scope of the invention. Further still, other aspects, functions and advantages are also within the scope of the invention; and all embodiments of the invention need not necessarily achieve all of the advantages or possess all of the characteristics described above. Additionally, steps, elements and features discussed herein in connection with one embodiment can likewise be used in conjunction with other embodiments. The contents of references, including reference texts, journal articles, patents, patent applications, etc., cited throughout the text are hereby incorporated by reference in their entirety; and appropriate components, steps, and characterizations from these references may or may not be included in embodiments of this invention. Still further, the components and steps identified in the Background section are integral to this disclosure and can be used in conjunction with or substituted for components and steps described elsewhere in the disclosure within the scope of the invention. In method claims, where stages are recited in a particular orderwith or without sequenced prefacing characters added for ease of referencethe stages are not to be interpreted as being temporally limited to the order in which they are recited unless otherwise specified or implied by the terms and phrasing.