Auxiliary station cooling unit for direct current fast charging

Abstract

A charging station for a vehicle, a system and method of charging a vehicle. The system includes a heat exchanger at the vehicle. The charging station includes a reservoir including a charging station coolant, a distributor unit configured to circulate the charging station coolant from the reservoir through the vehicle to absorb heat generated at the vehicle, and a cooling unit to cool the charging station coolant from the reservoir. Heat generated during charging of the vehicle is transferred into a vehicle coolant circulating within the vehicle. Heat is transferred from the vehicle coolant to the charging station coolant. The charging station coolant flows out of the vehicle.

Description

Technical Field

[0001] This subject matter disclosure relates to charging electric vehicles, and more specifically to systems and methods for dispersing heat generated during vehicle charging. Background Technology

[0002] Once its energy is depleted, the electric vehicle consumes the battery that needs charging. Charging the battery generates heat that is directly related to the rate at which charging occurs. Without thermal mitigation, the charging process can lead to thermal runaway. To reduce charging time, it is desirable to increase the charging rate, which results in higher charging temperatures. Therefore, it is desirable to provide a method to maintain the battery temperature below the runaway temperature limit during the charging process. Summary of the Invention

[0003] In one exemplary embodiment, a method for charging a vehicle is disclosed. Heat generated during vehicle charging is transferred to vehicle coolant circulating within the vehicle. Heat is transferred from the vehicle coolant to the charging station coolant. The charging station coolant flows out of the vehicle.

[0004] In addition to one or more features described herein, the method includes allowing charging station coolant to flow in a coolant circulation loop that includes a cooling unit outside the vehicle. The method also includes storing the charging station coolant in an underground storage location for ambient cooling. The method further includes connecting a hose to the vehicle, the hose including a connector having a first port and a second port, allowing charging station coolant to flow into the vehicle via the first port and out of the vehicle via the second port. The method also includes switching the configuration of a valve in the vehicle's internal circulation loop when the hose is connected to the vehicle. Switching the configuration includes placing a heat exchanger in the internal circulation loop to allow heat transfer from the vehicle coolant to the charging station coolant at the heat exchanger. The method also includes cooling the charging station coolant via either circulating the charging station coolant through a radiator outside the vehicle or transferring heat from the charging station coolant to a secondary coolant.

[0005] In another exemplary embodiment, a charging station for a vehicle is disclosed. The charging station includes a storage tank, a distributor unit, and a cooling unit. The storage tank includes a charging station coolant, the distributor unit is configured to circulate the charging station coolant from the storage tank through the vehicle to absorb heat generated at the vehicle, and the cooling unit is used to cool the charging station coolant from the storage tank.

[0006] In addition to one or more features described herein, the cooling unit is located externally to the vehicle. The storage tank is located underground. The charging station also includes a hose for connecting the distributor unit to the vehicle, the hose including a connector having a first port for allowing charging station coolant to flow into the vehicle and a second port for allowing charging station coolant to flow out of the vehicle. The charging station also includes an electronic control unit configured to send commands to valves in the vehicle's internal circulation loop to switch valve configurations when the hose is connected to the vehicle. Switching valve configurations includes placing a heat exchanger in the internal circulation loop to allow heat from the vehicle coolant to be transferred at the heat exchanger to the charging station coolant. The cooling unit also includes at least one of a radiator for cooling the charging station coolant from the storage tank and a condenser for cooling a secondary coolant that absorbs heat from the charging station coolant.

[0007] In yet another exemplary embodiment, a system for charging a vehicle battery is disclosed. The system includes a heat exchanger at the vehicle, a storage tank outside the vehicle, a distributor unit, and a cooling unit. The storage tank includes a charging station coolant, the distributor unit is configured to circulate the charging station coolant from the storage tank through the vehicle to absorb heat generated at the vehicle, and the cooling unit is used to cool the charging station coolant from the storage tank.

[0008] In addition to one or more features described herein, the reservoir is located underground. The system also includes a hose for connecting the distributor unit to the vehicle, the hose including a connector having a first port for allowing charging station coolant to flow into the vehicle and a second port for allowing charging station coolant to flow out of the vehicle. The system also includes an electronic control unit configured to send commands to valves in the vehicle's internal circulation loop to switch valve configurations when the hose is connected to the vehicle. Switching valve configurations includes placing a heat exchanger in the internal circulation loop to allow heat from the vehicle coolant to be transferred to the charging station coolant at the heat exchanger. The cooling unit also includes at least one of a radiator for cooling the charging station coolant from the reservoir and a condenser for cooling a secondary coolant that absorbs heat from the charging station coolant.

[0009] The above-described features and advantages, as well as other features and advantages of this disclosure, will become apparent when taken in conjunction with the accompanying drawings and the following detailed description. Attached Figure Description

[0010] Other features, advantages, and details appear by way of example only in the following specific embodiments, which are described in detail with reference to the accompanying drawings, wherein:

[0011] Figure 1 A charging station according to an exemplary embodiment is shown;

[0012] Figure 2A charging parking lot including multiple charging stations is shown in an embodiment;

[0013] Figure 3 A close-up view shows the connector of the distributor unit of the charging station and the docking point of the vehicle;

[0014] Figure 4 A schematic diagram of the vehicle's cooling system in the embodiment is shown;

[0015] Figure 5 The coolant circulation loop of the charging station in the embodiment is shown;

[0016] Figure 6 A charging station in an alternative embodiment is shown;

[0017] Figure 7 A close-up view of the vehicle's underside is shown;

[0018] Figure 8 A flowchart illustrating a method for controlling the flow of coolant through a vehicle at a charging station is shown; and

[0019] Figure 9 A flowchart illustrating a method for cooling fluid in a charging station is shown. Detailed Implementation

[0020] The following description is exemplary in nature only and is not intended to limit this disclosure, its application, or use. It should be understood that throughout the drawings, corresponding reference numerals denote the same or corresponding parts and features.

[0021] According to an exemplary embodiment, Figure 1 Charging station 100 is shown. Charging station 100 includes a distributor unit 102 and a hose 104 extending from distributor unit 102. A reservoir 106 for storing charging station coolant is located at charging station 100. In various embodiments, reservoir 106 is an underground reservoir. Distributor unit 102 circulates cold charging station coolant from reservoir 106 via hose 104 to vehicle 108 parked at charging station 100. Charging station coolant from charging station 100 is delivered to liquid-liquid heat exchanger 120. Charging station coolant absorbs heat generated during vehicle battery charging. Hot charging station coolant is then circulated from vehicle 108 back to reservoir 106 via hose 104 and distributor unit 102, where it is cooled.

[0022] The hose 104 includes a connector 110 at one end, which may include a non-overflow connector. The vehicle 108 has a docking station 112 for receiving the connector 110. The connector 110 is positioned in the docking station 112, allowing charging station coolant to circulate through the heat exchanger 120 of the vehicle 108 to cool the battery during charging. Although Figure 1 Although not shown, charging station 100 also includes a charging unit and a charging cable for charging the battery of vehicle 108. In various embodiments, the charging cable and hose 104 may be combined into a single hose assembly.

[0023] Figure 2 A charging parking lot 200, comprising multiple charging stations 100a-100e in an embodiment, is shown. The driver parks vehicle 108 at a selected charging station (e.g., charging station 100a) and connects the charging cable and hose 104 (…). Figure 1 The charging station 100a-100e is connected to the vehicle for charging. During charging, the charging station coolant 202 circulates from the storage tank 106 to the vehicle 108 and back to the storage tank. Each charging station 100a-100e is in fluid communication with the storage tank 106. Therefore, the charging station coolant can be shared from the storage tank 106 to any of the charging stations 100a-100e.

[0024] Figure 3 A close-up view 300 shows a connector 110 of the distributor unit 102 and a docking station 112 of the vehicle 108. The connector 110 includes a first port 302 and a second port 304. The docking station 112 includes an input socket 306 and an output socket 308. When the connector 110 is connected to the docking station 112, the first port 302 is inserted into the input socket 306 to form a sealed inflow channel, and the second port 304 is inserted into the output socket 308 to form a sealed outflow channel. Charging station coolant 202 flows into the vehicle 108 via the first port 302 and the input socket 306, and flows out of the vehicle via the output socket 308 and the second port 304. In various embodiments, the docking station 112 may be located near the charging docking station 310 that receives the charging cable.

[0025] Figure 4 A schematic diagram 400 of the cooling system of vehicle 108 in an embodiment is shown. Schematic diagram 400 shows an interior region 402 located within or on vehicle 108 and an exterior region 404 located outside the vehicle. A partition 406 shows the location where connector 110 inserts into mating seat 112. The location where charging station coolant 202 enters vehicle 108 is indicated by a first port 302 and input socket 306, and the location where coolant leaves the vehicle is indicated by a second port 304 and output socket 308. Charging station coolant 202 enters vehicle 108 at a low temperature (e.g., 20 degrees Celsius). Coolant 202 passes through heat exchanger 120 and leaves vehicle 108 at a high temperature (e.g., 30 degrees Celsius) while absorbing energy from vehicle coolant 420. Heat exchanger 120 is located inside or on vehicle 108.

[0026] Interior region 402 includes an internal coolant circuit 410. The internal coolant circuit 410 includes a pump 412, a valve 414, a cooler 416, and a rechargeable energy storage system (RESS) (such as a battery 418). Vehicle coolant 420 circulates through the internal coolant circuit 410 via the pump 412. The valve 414 can switch between a first configuration and a second configuration. In the first configuration, the internal coolant circuit 410 includes the pump 412, valve 414, cooler 416, and battery 418. In the first configuration, only the cooler 416 is used to cool the vehicle coolant 420. In the second configuration, the internal coolant circuit 410 includes the pump 412, valve 414, cooler 416, battery 418, and heat exchanger 120. During battery charging, the valve 414 switches to the second configuration to include the use of the heat exchanger 120.

[0027] When connector 110 is engaged with mating seat 112, valve 414 can switch from a first configuration to a second configuration. Removing connector 110 from mating seat 112 switches valve 414 back to the first configuration. In one embodiment, when connector 110 is placed in mating seat 112, connector 110 applies force to valve 414 to mechanically switch the valve from the first configuration to the second configuration. Removing connector 110 removes the force, thereby allowing the valve to switch back to the first configuration. In another embodiment, valve 414 can switch to the second configuration upon receiving an electronic signal transmitted by connector 110. This signal can be transmitted when connector 110 is secured to mating seat 112 or when connector 110 is within a selected distance of mating seat 112 and / or valve 414.

[0028] In the first configuration of valve 414, vehicle coolant 420 circulates between battery 418 and cooler 416 to cool the battery during normal vehicle operation. When valve 414 is in the second configuration, vehicle coolant 420 passes through heat exchanger 120. Heat generated at battery 418 during charging is transported via vehicle coolant 420 to heat exchanger 120, where it is transferred to charging station coolant 202. Charging station coolant 202 then circulates out of vehicle 108, thereby removing heat from battery 418 and maintaining battery 418 at a sufficiently low temperature to prevent overheating (i.e., below battery runaway temperature).

[0029] Figure 5A coolant circulation loop 500 of the charging station 100 in the embodiment is shown. The coolant circulation loop 500 includes a non-insulated underground storage tank 502, an insulated storage tank 504, and a cooling unit 506. Charging station coolant 202 returning from vehicle 108 deposits into the non-insulated underground storage tank 502, where its temperature stabilizes to the ground temperature. Charging station coolant 202 circulates from the non-insulated underground storage tank 502 to either the cooling unit 506 or the insulated storage tank 504 for additional cooling.

[0030] Cooling unit 506 includes a first cooling system 508 and a second cooling system 510. The first cooling system 508 includes a radiator 512 and a fan 514. The second cooling system 510 includes a pump 516, a compressor 518, a condenser 520, and a cooler 522. The fan 514 may also be used in conjunction with the second cooling system 510. In one configuration, charging station coolant 202 from a non-insulated underground storage tank 502 circulates through the radiator 512 for cooling. The fan 514 blows ambient air across the radiator 512 to draw heat away from the charging station coolant 202. In another configuration, charging station coolant 202 from a non-insulated underground storage tank 502 circulates to an insulated storage tank 504, where heat is transferred from the charging station coolant 202 to a secondary coolant 524. Then, the secondary coolant 524 circulates from the adiabatic reservoir 504 through the second cooling system of the cooling unit 506, where it is cooled before returning to the adiabatic reservoir 504. The fan 514 can be operated to promote condensation in the condenser 520.

[0031] In various embodiments, the secondary coolant 524 may be a phase change material. A second cooling system 510 is used to maintain the phase change material at a low temperature. In one embodiment, the phase change material is ice / water, and the second cooling system 510 maintains the water at approximately 0 degrees Celsius. A pump 516 circulates the secondary coolant 524 between an adiabatic reservoir and the second cooling system 510.

[0032] Coolant valve 526 in coolant circulation loop 500 switches between a first configuration and a second configuration. In the first configuration, charging station coolant 202 is guided from non-insulated underground storage 502 to the first cooling system 508 of cooling unit 506. At cooling unit 506, charging station coolant 202 passes through radiator 512, where it is cooled. Charging station coolant 202 then circulates back to distributor unit 102 and the vehicle. Charging station coolant 202 passes through filter 528 at distributor unit 102. Distributor pump 530 at distributor unit 102 circulates coolant 202 into vehicle 108. Figure 1 ).

[0033] In the second valve configuration, charging station coolant 202 is guided from non-insulated underground storage 502 to insulated storage 504. At insulated storage 504, coolant 202 exchanges heat with secondary coolant 524 for cooling. Coolant 202 is then sent to the distribution station via filter 528 and distribution pump 530. Simultaneously, secondary coolant 524 is pumped from insulated storage 504 through a second cooling system 510, which maintains the temperature of the secondary coolant within a given temperature range. A buffer tank 540 is available to handle overflows within the second cooling system 510.

[0034] Electronic control unit 532 communicates with various components of the coolant circulation loop 500, such as fan 514, compressor 518, pump 516, distribution pump 530, and valve 526. Electronic control unit 532 controls the operation of these components to maintain the operation of the coolant circulation loop 500. For example, when the ambient temperature is below a selected temperature, valve 526 may be positioned in a first configuration to direct coolant to radiator 512. When the ambient temperature is greater than or equal to the selected temperature, valve 526 may be positioned in a second configuration to circulate coolant to adiabatic reservoir 504. In various embodiments, the selected temperature is room temperature (e.g., 25 degrees Celsius).

[0035] In various embodiments, the electronic control unit 532 also communicates with valve 414 of the refrigerant circulation loop 410 of the vehicle 108 and can send control signals to the valve to change its configuration.

[0036] Figure 6 A charging station 600 in an alternative embodiment is shown. The charging station 600 includes a distributor unit 102 and a trolley 602 that can roll under a vehicle 108 when the vehicle is parked at the charging station. A docking seat is located at the bottom portion 604 of the vehicle 108 for fluid transfer.

[0037] Figure 7 A close-up view 700 of the bottom portion 604 of vehicle 108 is shown. The bottom portion 604 includes a door 702 that can be opened and closed to expose or conceal the docking seat. In various embodiments, the door 702 may be a sliding door.

[0038] A first hose 704 extends from the trolley 602 to the distributor unit 102, and a second hose 706 extends from the trolley to the distribution system. At the trolley 602, the first hose 704 terminates at a first port 302, and the second hose terminates at a second port 304. When the trolley is positioned under the vehicle 108, a door 702 can be opened to expose an input socket 306 and an output socket 308. The trolley 602 can be arranged such that the first port 302 can be hermetically connected to the input socket 306, and the second port 304 can be hermetically connected to the output socket 308. Coolant 202 can then be supplied from the reservoir (106, ) via the first hose 704, the first port 302, and the input socket 306. Figure 1 The coolant is pumped into vehicle 108. Coolant is removed from vehicle 108 and sent to reservoir 106 via output socket 308, second port 304, and second hose 706. Figure 1 ).

[0039] Figure 8 A flowchart 800 illustrates a method for controlling the flow of coolant 202 from a charging station through a vehicle. In block 802, a test is performed to check if the coolant connector is connected to the vehicle. If the connector is not connected, the method proceeds to block 804. In block 804, no action is taken, and the method returns to block 802. If, at block 802, the connector is found to be connected to the vehicle, the method proceeds to block 806. In block 806, the battery temperature is measured. If the temperature is greater than an ambient temperature threshold (e.g., 25 degrees Celsius), the method proceeds to blocks 808 and 810. In block 808, valve 414 is placed in a second configuration to include heat exchanger 120 in the internal coolant circuit. In block 810, the number of vehicles requiring cooling at the charging station is counted. In block 812, the pumping rate of the charging station coolant is adjusted to accommodate the number of vehicles requiring cooling. In one embodiment, the number of charging vehicles n is multiplied by the standard pump rate of a single vehicle (e.g., 15 liters / minute) to obtain a combined pump rate (e.g., n*15 liters / minute).

[0040] In box 814, the charging station's fan is turned on to activate cooling of the charging station's coolant. In box 816, an operating mode for cooling the charging station's coolant is selected. If the ambient temperature is below the selected ambient temperature threshold (e.g., 25 degrees Celsius), the method proceeds to box 818. Otherwise, the method proceeds to box 820.

[0041] In block 818, coolant valve 526 is switched to a first configuration, allowing charging station fluid 202 to flow through the radiator. In block 820, coolant valve 526 is switched to a second configuration, allowing charging station fluid 202 to flow through the adiabatic reservoir 504.

[0042] Therefore, the charging station coolant 202 is cooled based on the charging station's ability to cool the coolant 202 to the desired temperature. If there is sufficient capacity to directly dissipate heat into the air, radiator cooling is selected. Otherwise, the use of a cooler is chosen. This selection of cooling method optimizes the cooling process.

[0043] Figure 9 A flowchart 900 illustrating a method for cooling fluid in a charging station is shown. In block 902, a test is performed to determine the ambient temperature. If the ambient temperature is below an ambient temperature threshold (e.g., 25 degrees Celsius), the method proceeds to block 904. At block 904, no action is taken, and the method returns to block 902. If at block 902 the ambient temperature is greater than or equal to the ambient temperature threshold, the method proceeds to block 906. At block 906, the temperature of the adiabatic reservoir or secondary coolant is checked. If the secondary coolant temperature is below the phase change temperature (e.g., 0 degrees Celsius), the method proceeds to block 904, where no action is taken. If at block 906 the secondary coolant temperature is below the phase change temperature, the method proceeds to block 908. At block 908, the compressor is turned on. At block 910, the stationary fan is turned on. At block 912, pump 516 is turned on to circulate the secondary coolant.

[0044] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A method for charging a vehicle, comprising: The heat generated during the charging of the vehicle is transferred to the vehicle coolant circulating within the vehicle. Heat is transferred from the vehicle's coolant to the charging station's coolant; as well as This allows the coolant from the charging station to flow out of the vehicle. The system allows the charging station coolant to flow in a coolant circulation loop, which includes a non-insulated underground storage tank, an insulated storage tank, and a cooling unit. The coolant valve in the coolant circulation loop is switched between a first configuration and a second configuration. In the first configuration, the charging station coolant is guided from a non-insulated underground storage tank to a cooling unit, where it passes through a radiator and is cooled. In the second configuration, the charging station coolant is guided from a non-insulated underground storage tank to an insulated storage tank, where it exchanges heat with a secondary coolant for cooling, wherein the secondary coolant is cooled by a condenser.

2. The method according to claim 1, further comprising: A hose is connected to the vehicle, the hose including a connector having a first port and a second port; The charging station coolant flows into the vehicle through the first port; as well as The charging station coolant flows out of the vehicle through the second port.

3. The method according to claim 2, further comprising: When the hose is connected to the vehicle, it switches the configuration of the valve in the vehicle's internal circulation loop.

4. The method according to claim 3, wherein, Switching the configuration includes placing a heat exchanger in the internal circulation loop to allow heat to be transferred from the vehicle coolant to the charging station coolant at the heat exchanger.

5. A charging station for vehicles, comprising: A non-insulated underground storage unit, the non-insulated underground storage unit including a charging station coolant; A distributor unit configured to circulate charging station coolant from the non-insulated underground storage tank through the vehicle to absorb heat generated at the vehicle. A cooling unit having a radiator for cooling the charging station coolant from the non-insulated underground storage tank, the cooling unit also having a condenser for cooling a secondary coolant that absorbs heat from the charging station coolant; Insulated storage unit; as well as A coolant valve capable of switching between a first configuration and a second configuration, in which the charging station coolant is guided from a non-insulated underground storage tank to a cooling unit, where it passes through a radiator and is cooled; and in the second configuration, where the charging station coolant is guided from a non-insulated underground storage tank to an insulated storage tank, where it exchanges heat with a secondary coolant for cooling.

6. The charging station of claim 5 further includes a hose for connecting the distributor unit to the vehicle, the hose including a connector having a first port for allowing charging station coolant to flow into the vehicle and a second port for allowing charging station coolant to flow out of the vehicle.

7. The charging station of claim 6 further includes an electronic control unit configured to send a command to a valve in the vehicle's internal circulation loop to switch the configuration of the valve when the hose is connected to the vehicle.

8. The charging station according to claim 7, wherein, Switching the configuration of the valve includes placing a heat exchanger in the internal circulation loop to allow heat from the vehicle coolant to be transferred at the heat exchanger to the charging station coolant.

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