EV charging station capable of off-grid operation, control system for EV charging station and method of managing power supply of EV charging station

Abstract

An EV charging plant includes one or more chargers, and one or more hydrogen-powered fuel cells and one or more storage batteries as power sources, and optionally connections to one or more of a grid, photovoltaic or wind power plant. The station further includes a control system configured to control and manage the power source. The control system takes into account one or more of a current availability of the power source, power available from the currently available power source, a current price of power from the available power source, an environmental impact of the available power source, a current and / or predicted energy demand at the charger, and an EV current or desired charging speed.

Description

Technical Field

[0001] The present invention relates to an electric vehicle (EV) charging station capable of off-grid operation, a control system for the EV charging station, and a method of controlling and managing power supply of the EV charging station. Background Art

[0002] With the significant increase in the number of electric vehicles in the past few years, EV charging is developing rapidly, growing rapidly year by year. Direct current (DC) fast charging at charging stations has become a real need for fast recharging "on the go", but requires the availability of high power sources. However, high power availability is currently lacking in many places. There are still many places with only weak power grids or no grid at all, especially (but not exclusively) in rural and more remote areas. Even if it is theoretically possible to upgrade, it can take 18 to 24 months to build a new charging infrastructure.

[0003] In view of the foregoing and the ever-increasing number of EVs on the road, there is an urgent need for charging stations for EVs that can be placed even in areas where a power grid is weak or not available at all. Summary of the Invention

[0004] The present invention provides an EV charging station power and energy source comprising (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries for energy storage. The charging station also includes a connection to (iii) an electric grid. The charging station further includes a control system configured to control and manage the power sources present in the charging station. In doing so, the control system takes into account one or more of the following: (a) the current availability of each of the power sources (i) to (iii); (b) the power available from each of the currently available power sources; (c) the current price of power from each available power source; (d) the environmental impact of the available power sources (carbon footprint, availability of renewable energy, etc.); (e) the current and / or predicted energy demand at one or more chargers; and (f) the current and / or expected EV charging speed.

[0005] In one embodiment of the charging station, the control system takes into account at least two of factors (a) to (f). For example, the control system takes into account at least factors (b) and (e), at least factors (b), (c), and (e), at least factors (b), (d), and (e), or at least factors (b), (c), (d), and (e).

[0006] In one embodiment, power source (i) comprises one or more alkaline fuel cells, and / or power source (ii) comprises one or more lithium iron phosphate (LFP) batteries.

[0007] In one embodiment, the charging station comprises a connection to an electricity grid (iii) and / or a connection to a photovoltaic system (iv).

[0008] The charging station will typically also include a storage unit for hydrogen as fuel for power source (i). Alternatively or additionally, the charging station may be supplied with hydrogen via a pipeline. Alternatively or additionally, the charging station may include a storage unit (and / or pipeline) for ammonia, in which case the storage unit is combined with a unit capable of thermally decomposing the ammonia into hydrogen and nitrogen.

[0009] In one embodiment of the charging station, the control system causes the charging station to: (1) operate in a mode in which the one or more chargers charge one or more EVs using power from power source (iii) and / or power from power source (ii) but not using power from power source (i), and / or (2) operate in a mode in which the one or more chargers charge one or more EVs using power from power source (ii) and / or power source (iii) and / or power source (iv) and / or power source (v) and activate power source (i) only if the predicted demand for charging energy cannot be met by the other available power sources alone, and / or (3) operate in a mode in which the one or more chargers charge one or more EVs using power from power source (ii) and / or power source (iii) and / or power source (iv) and / or power source (v) and, optionally, power from power source (i) and reduce the charging load if the current demand for charging power cannot be met by the available power sources.

[0010] In one embodiment of the charging station, if power source (ii) is at least partially discharged, the control system causes one or more of the available remaining power sources to at least partially recharge (ii), while not requiring the available remaining power sources to charge one or more EVs.

[0011] The present invention also provides a control system for an EV charging station, the EV charging station including one or more EV chargers and (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries as power sources, and optionally a connection to one or more of (iii) an electric grid, (iv) a photovoltaic device, or (v) a wind power device. The control system is configured to control and manage the power sources and take into account one or more of the following: (a) the current availability of each of the power sources (i) to (v); (b) the power available from (each) currently available power source; (c) the current price of power from (each) available power source; (d) the environmental impact of (each) available power source; (e) the current and / or predicted charging energy demand at one or more charging stations; and (f) the current and / or expected EV charging speed.

[0012] Particular embodiments of the control system include all embodiments stated above in conjunction with the charging station of the present invention.

[0013] The present invention further provides a method of controlling and managing the power supply of an EV charging station, the EV charging station comprising one or more EV chargers and (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries as power sources, and optionally a connection to one or more of (iii) an electric grid, (iv) a photovoltaic device, or (v) a wind power device. The method comprises controlling and managing the power supply while taking into account one or more of the following: (a) the current availability of (each) power source (i) to (v); (b) the power available from (each) currently available power source; (c) the current price of power from (each) available power source; (d) the environmental impact of (each) available power source; (e) the current and / or predicted charging energy demand at one or more charging stations; and (f) the current and / or expected EV charging speed.

[0014] Particular embodiments of the above method include the embodiments set forth above in conjunction with the charging station of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The invention is further described in the following detailed description by way of non-limiting examples of exemplary embodiments of the invention with reference to the accompanying drawings. In the drawings:

[0016] Figure 1 Components of an exemplary charging station of the present invention are schematically shown. DETAILED DESCRIPTION

[0017] The details presented herein are presented by way of example only and for the purpose of illustrative discussion of embodiments of the present invention and in order to provide what is believed to be the most useful and easy description of the principles and conceptual inventions of the present invention. In this regard, no attempt is made to show the structural details of the present invention in more detail than is necessary for a basic understanding of the present invention, and the description with the aid of the drawings will enable those skilled in the art to understand how the several forms of the present invention may be embodied in practice.

[0018] As described above, the present invention provides, inter alia, an EV charging station comprising (i) one or more (e.g., one, two, three, four, five, six, or more) hydrogen-powered fuel cells and (ii) one or more (e.g., one, two, three, four, five, six, or more) batteries as power sources. Optionally (and preferably), the charging station further comprises a connection to one or more of (iii) an electrical grid, (iv) a photovoltaic system, or (v) a wind turbine. The charging station further comprises a control system configured to control and manage the power source. In doing so, the control system takes into account one or more of the following: (a) the current availability of (each) power source (i) to (v); (b) the power available from (each) currently available power source; (c) the current price of power from (each) available power source; (d) the environmental impact (carbon footprint, availability of renewable energy, etc.) of (each) available power source; (e) the current and / or predicted demand for charging power at one or more chargers; and (f) available and / or desired EV charging speeds.

[0019] In one embodiment of the charging station, the control system takes into account at least two (e.g., two, three, four, five, or six) of the factors (a) to (f). For example, the control system takes into account at least factors (b) and (e), at least factors (b), (c), and (e), at least factors (b), (d), and (e), or at least factors (b), (c), (d), and (e).

[0020] Power source (i) may include or consist of one or more (e.g., one, two, three, four, or more) alkaline fuel cells, and / or power source (ii) may include or consist of one or more (e.g., one, two, three, four, or more) lithium iron phosphate (LFP) batteries. Of course, other battery types, such as nickel-cadmium (Ni-Cd), nickel-metal hydride (Ni-MH), and lithium-ion (Li-Ion) batteries, as well as combinations of different types, may also be used, but this is generally not preferred. LFP batteries are preferably used, particularly because they are capable of high-speed charging and discharging and are characterized by higher power density, lower discharge rates, lower heat generation, and a higher number of charge cycles compared to other battery types, generally resulting in increased safety and resilience.

[0021] The hydrogen and / or ammonia used in the one or more fuel cells is preferably green and / or blue hydrogen / ammonia, for example hydrogen formed by electrolysis of water using electricity generated by photovoltaic and / or wind power plants.

[0022] If the charging station includes a connection to a photovoltaic system (iv), then the photovoltaic system may be part of the charging station. For example, the photovoltaic system may include solar panels on a rooftop that covers the charging station or even the entire charging station or a portion thereof. Of course, the photovoltaic system may also be located remote from the charging station.

[0023] Due to the presence / availability of power sources (i) and (ii) (and optionally power sources (iv) and / or (v)), connection to the grid (iii) is preferred but not absolutely necessary, as the charging station can charge EVs even when the grid is not available. Whenever the grid is available, it is generally preferred to connect the charging station to the grid. In this case, it is also possible to feed excess energy, such as energy generated by a photovoltaic system that is not required for charging either the battery or batteries (ii) or the EV or EVs, back to the grid and thereby receive a refund or credit from the electricity supplier.

[0024] The charging station will typically also include a storage system for hydrogen, which serves as the fuel for power source (i). The storage system may comprise, for example, several hydrogen cylinders. Alternatively or additionally, the charging station may be supplied with hydrogen via a pipeline. Alternatively or additionally, the charging station may include a storage system for ammonia (and / or supply it via a pipeline), in which case the storage system is combined with a system capable of thermally decomposing the ammonia into hydrogen and nitrogen.

[0025] The control and management of the power sources (i) to (v) comprises, in particular, determining which of the available power sources are to be employed in predefined situations and the purpose for which they are employed (e.g. directly by providing energy to a charger or indirectly by charging one or more batteries (ii)).

[0026] For example, in one embodiment of a charging station, the control system causes the charging station to: (1) operate in a mode in which one or more chargers charge one or more EVs using power from (iii) and / or power from (ii) but not using power from (i), and / or (2) operate in a mode in which one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v) and activate (i) only if the predicted demand for charging energy cannot be met by other available power sources alone, and / or (3) operate in a mode in which one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v) and, optionally, power from (i) and reduce the charging load if the current demand for charging power cannot be met by the available power sources.

[0027] By way of example only, the charging station may operate in at least one of the following energy / power modes:

[0028] Sufficient energy and power mode:

[0029] - The EV is being charged using energy from power source (ii) and from power source (iii) (if available).

[0030] - One or more fuel cells (i) are inactivated because there is sufficient energy to meet current (and predicted) demand.

[0031] - Energy is not returned to the grid in any way.

[0032] Insufficient energy mode:

[0033] - The EV is being charged using energy from power source (ii) and from power source (iii) (if available) (and optionally also using energy from (iv) and / or (v) (if present)).

[0034] - The control system (energy management system) predicts that a predefined "insufficient energy state" will soon occur and signals one or more fuel cells (i) to start up, so that as soon as the one or more fuel cells (i) are ready (after a short start-up period), they can provide additional energy.

[0035] - One or more fuel cells (i) initiate a start-up sequence to be able to provide supplemental energy.

[0036] Insufficient power mode:

[0037] - The control system determines that the power demand is approaching a point where all available power sources will no longer be sufficient to meet the power demand.

[0038] -The charging load of the charger is reduced.

[0039] In one embodiment of the charging station, if power source (ii) is at least partially discharged, the control system may cause one or more of the available remaining power sources to at least partially recharge power source (ii), while not requiring the available remaining power source to charge one or more EVs. For example, the control system may cause one or more of power sources (iii) to (v), if available, to at least partially recharge power source (ii), while not requiring power sources (i) to (v) to charge one or more EVs. In this regard, it should be noted that electricity from power source (i) is typically more expensive than electricity from power sources (iii), (iv), or (v), for example, due to the fact that (compressed) hydrogen (or ammonia) must be transported to the charging station site (typically by truck) and the associated transportation and logistics costs. Keeping one or more batteries (ii) fully or nearly fully charged as much as possible and charging one or more batteries with electricity from the cheapest available power source whenever possible is one way to increase (improve) the economics of the charging station.

[0040] Therefore, it is usually most cost-effective to avoid using power source (i) (if possible) and adopt power sources (iii) and / or (iv) and / or (v). If power sources (iii) to (v) are unavailable or insufficient to meet the current power demand, power source (ii) can provide almost instant power. If the available power sources (ii) to (v) are insufficient to meet the current charging power demand, power source (i) is usually best used to provide backup power.

[0041] It should be taken into account here that power source (i) is usually not available instantaneously, as it requires some time to start up. In view of this, it is advantageous for charging stations to have the ability to predict power demand based on predetermined time profiles (e.g., 24h (daily) and 168h (weekly) profiles) using (1) the predicted availability of power (especially with respect to power sources (iv) and (v), but also with respect to power source (iii)) and (2) the predicted site consumption (especially based on EV charging patterns, but optionally also as a backup for critical assets such as hospitals, first responders, POS machines, IT, etc.).

[0042] Figure 1 is a schematic representation of an exemplary charging station for six chargers according to the present invention. Each of the chargers may, for example, provide up to 75 kW (scalable from 25 kW to 75 kW depending on, for example, the number of chargers in use).

[0043] Figure 1 The abbreviations shown have the following meanings:

[0044] ENM Electrical Network Manager

[0045] EMS Energy Management System

[0046] SCADA monitoring control and data acquisition

[0047] NMS Network Management System

[0048] PV photovoltaic equipment

[0049] BESS Battery Energy Storage System

[0050] PCS Power Conversion System

[0051] As from Figure 1 As can be seen in the figure, the charging station includes four hydrogen-powered alkaline fuel cells, each providing 48V DC and 5kW (in parallel, a total of 20kW). The output voltage of each fuel cell can be increased to, for example, 700V DC by using a DC / DC converter. The hydrogen used for the fuel cells can be stored in, for example, 64 (easily replaceable) cylinders. A typical cylinder bundle of 64 50L@300Bar cylinders will provide 920kWh of energy storage. The system is scalable because more than four fuel cells can be used, for example five, six or more fuel cells. The amount of fuel cell and battery energy storage typically increases with the number of chargers present in the charging station. A switching system can also be provided that manages the flow of hydrogen between cylinder bundles and automatically calls for replacement cylinders when needed.

[0052] In the illustrated embodiment, power source (ii) takes the form of several LFP batteries with a basic total storage capacity of 372.2 kWh. This battery energy storage system (BESS) allows excess power from other power sources (grid, photovoltaic systems and / or fuel cells) to be stored and used according to a defined operating logic.

[0053] The use of grid connection elements using a power conversion system (PCS) allows the charging station to be connected to the grid when it is available. This allows the provision of 180kW to 350kW. This also enables customers to sell excess power back to the grid and operate the charging station as a peak load support device.

[0054] The PV connection in the main panel allows the charging station to add additional boosters as needed to handle PV equipment. The coupling (DC or AC) will be defined according to the existing site layout.

[0055] The main Energy Management System (EMS) control unit manages and controls the charging station components and power sources to allow maximum balance and efficiency while prioritizing the different power sources. The main EMS control unit can also be connected to any standard external monitoring system.

[0056] In summary, instant charging stations may provide one or more of the following features / advantages:

[0057] ● Ensure maximum power availability for fast DC chargers even when the grid is weak or unavailable.

[0058] ● Control and activate multiple power sources (grid, PV, batteries, wind) as well as local power generation using fuel cells.

[0059] ● Planning and forecasting energy availability

[0060] ○ Forecast estimated demand: weekdays, weekends, seasonality

[0061] ○ Forecast estimated generation: PV radiation, wind power, grid availability

[0062] ○ When the driver reserves a charger, prepare energy in advance.

[0063] ○ Predict energy costs.

[0064] Software for:

[0065] o Ensure power availability in advance (generate and store energy). Advance = pre-booking or location prediction.

[0066] ○Techno-economic electricity distribution (variable grid pricing, electricity generation costs).

[0067] o Dynamically price energy to end customers based on current energy generation costs and availability.

[0068] ○ Connect to CPMS (Charge Point Management System) to:

[0069] ■ DLM (Dynamic Load Management) of chargers for high frequency updates of available power to all chargers (DLM spreads power across active chargers when there is not enough power).

[0070] ■Read charger usage information to predict station usage patterns.

[0071] ■Read reservation information.

[0072] o Manage multiple battery banks and capacitors in different C-class groups (0.5 to 4C). This enables economical operation of ultra-fast chargers for high-power and industrial EVs.

Claims

1. An electric vehicle (EV) charging station, wherein the station includes one or more EV chargers and (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries as power sources, and optionally a connection to one or more of (iii) an electric grid, (iv) a photovoltaic device, or (v) a wind device, and wherein the charging station further includes a control system configured to control and manage the power sources, the control system taking into account one or more of the following: (a) the current availability of power sources (i) to (v); (b) the power available from the currently available power sources; (c) the current price of power from the available power sources; (d) the environmental impact of the available power sources; (e) the current and / or predicted energy demand at the one or more chargers; and (f) the EV charging speed.

2. The charging station of claim 1, wherein the control system takes into account at least two of (a) to (f).

3. The charging station of claim 1, wherein the control system takes into account at least (b) and (e).

4. A charging station according to any one of claims 1 to 3, wherein (i) comprises one or more alkaline fuel cells.

5. A charging station according to any one of claims 1 to 4, wherein (ii) comprises one or more lithium iron phosphate (LFP) batteries.

6. The charging station of any one of claims 1 to 5, wherein the charging station comprises a connection to at least one of (iii), (iv) and (v).

7. A charging station according to any one of claims 1 to 6, wherein the charging station comprises a connection to at least (iii).

8. The charging station according to any one of claims 1 to 6, wherein the charging station comprises a connection to at least (iii) and / or (iv).

9. The charging station according to any one of claims 1 to 8, wherein the charging station further comprises a hydrogen storage unit for (i).

10. The charging station of any one of claims 1 to 9, wherein the control system is capable of causing the charging station to operate in a mode in which the one or more chargers charge one or more EVs using power from (iii) and / or power from (ii) but not power from (i).

11. The charging station of any one of claims 1 to 10, wherein the control system is capable of causing the charging station to operate in a mode in which the one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v), and (i) is activated only if the predicted demand for charging energy cannot be met by the other available power sources alone.

12. A charging station according to any one of claims 1 to 11, wherein the control system is capable of causing the charging station to operate in a mode in which the one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v) and optionally power from (i) and reduce the charging load if the current demand for charging energy cannot be met by the available power sources.

13. A charging station according to any one of claims 1 to 12, wherein if (ii) is at least partially discharged, the control system is capable of causing one or more of the available remaining power sources to at least partially recharge (ii) without requiring the available remaining power source to charge one or more EVs.

14. A charging station according to any one of claims 1 to 13, wherein if (ii) is at least partially discharged, the control system is capable of causing one or more of (iii) to (v) to at least partially recharge (ii) if available, without requiring (i) to (v) to charge one or more EVs.

15. A control system for an EV charging station, the EV charging station comprising (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries as power sources, and optionally a connection to one or more of (iii) an electrical grid, (iv) a photovoltaic device, or (v) a wind device, wherein the control system is configured to control and manage the power sources and take into account one or more of: (a) the current availability of power sources (i) to (v); (b) the power available from the currently available power sources; (c) the current price of power from the available power sources; (d) the environmental impact of the available power sources; (e) the current and / or predicted charging energy demand at one or more charging stations; and (f) the EV charging speed.

16. The control system of claim 15, wherein the control system takes into account at least two of (a) to (f).

17. The control system of claim 15, wherein the control system takes into account at least (b) and (e).

18. A control system according to any one of claims 15 to 17, wherein the control system is capable of causing the charging station to operate in a mode in which one or more chargers utilize power from (iii) and / or power from (ii) but not power from (i) to charge one or more EVs.

19. A control system according to any one of claims 15 to 18, wherein the control system is capable of causing the charging station to operate in a mode in which the one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v) and (i) is activated only if the predicted demand for charging energy cannot be met by the other available power sources alone.

20. A control system according to any one of claims 15 to 19, wherein the control system is capable of causing the charging station to operate in a mode in which the one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v) and optionally power from (i) and reduce the charging load if the current demand for charging energy cannot be met by the available power sources.

21. A control system according to any one of claims 15 to 20, wherein if (ii) is at least partially discharged, the control system is capable of causing one or more of the available remaining power sources to at least partially recharge (ii) without requiring the available remaining power sources to charge one or more EVs.

22. A control system according to any one of claims 15 to 21, wherein if (ii) is at least partially discharged, the control system is capable of causing one or more of (iii) to (v) to at least partially recharge (ii) if available, without requiring (iii) to (v) to charge one or more EVs.

23. A method of controlling and managing the power supply of an EV charging station, the EV charging station comprising one or more EV chargers and (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries as power sources, and optionally a connection to one or more of (iii) an electric grid, (iv) a photovoltaic device, or (v) a wind power device, wherein the method comprises controlling and managing the power supply while taking into account one or more of: (a) the current availability of power sources (i) to (v); (b) the power available from the currently available power sources; (c) the current price of power from the available power sources; (d) the environmental impact of the available power sources; (e) the current and / or predicted charging energy demand at one or more charging stations; and (f) the EV charging speed.

24. The method of claim 23, wherein at least two of (a) to (f) are taken into account.

25. The method of claim 23, wherein at least (b) and (e) are taken into account.

26. The method of any one of claims 23 to 25, wherein the charging station is caused to operate in a mode in which one or more chargers utilize power from (iii) and / or power from (ii) but not power from (i) to charge one or more EVs.

27. A method according to any one of claims 23 to 26, wherein the charging station is caused to operate in a mode in which the one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v) and (i) is activated only if the predicted demand for charging energy cannot be met by the other available power sources alone.

28. A method according to any one of claims 23 to 27, wherein the charging station is caused to operate in a mode in which the one or more chargers charge one or more EVs using power from (ii) and / or (iii) and / or (iv) and / or (v) and optionally power from (i) and reduce the charging load if the current demand for charging energy cannot be met by the available power sources.

29. The method of any one of claims 23 to 28, wherein if (ii) is at least partially discharged, one or more of the available remaining power sources are caused to at least partially recharge (ii) while not requiring the available remaining power source to charge one or more EVs.

30. The method of any one of claims 23 to 29, wherein if (ii) is at least partially discharged, causing one or more of (iii) to (v) to at least partially recharge (ii) if available, while not requiring (iii) to (v) to charge one or more EVs.

Images