Dark start support verification

Abstract

The present disclosure provides "dark start support verification". A combiner box disables a primary power converter of the combiner box if grid power is available to the combiner box and the combiner box is connected with an electric vehicle power supply equipment, enables a backup power converter of the combiner box, and sends a signal to the electric vehicle power supply equipment. This causes a primary power converter of the electric vehicle power supply equipment to be disabled, a standby power converter of the electric vehicle power supply equipment to be enabled, and power from the combiner box that provides power to start a standby power source of a home energy system when the grid power is unavailable flows to the electric vehicle power supply equipment.

Description

Technical Field

[0001] This disclosure relates to power management. Background Technology

[0002] Electric vehicles can be one of several sources of power that provide backup power to homes when the power grid becomes unavailable. Summary of the Invention

[0003] A home energy system includes: a combiner box that, when grid power is available to the combiner box and the combiner box is connected to an electric vehicle power supply unit, disables the main power converter of the combiner box, enables the backup power converter of the combiner box, and sends a signal to the electric vehicle power supply unit such that the main power converter of the electric vehicle power supply unit is disabled, the backup power converter of the electric vehicle power supply unit is enabled, and power from the combiner box that provides power to start the home energy system's backup power supply unit when grid power is unavailable flows to the electric vehicle power supply unit.

[0004] A method includes: in response to the occurrence of a predefined condition when grid power is available for a combiner box and the combiner box is connected to an electric vehicle power supply device, disabling the main switch mode power supply of the combiner box, enabling the standby switch mode power supply of the combiner box, and sending a signal to the electric vehicle power supply device such that the electric vehicle power supply device consumes power from the combiner box via Ethernet to provide power to start the battery of a home energy system including the combiner box when grid power is unavailable.

[0005] A combiner box includes: a main switch-mode power supply and a standby switch-mode power supply; a battery that provides power to start a home energy system including the combiner box; and a microprocessor that disables the main switch-mode power supply, enables the standby switch-mode power supply, and then supplies power from the battery to the electric vehicle power supply when grid power is available for the combiner box and the combiner box is connected to an electric vehicle power supply device. Attached Figure Description

[0006] Figure 1 This is a schematic diagram of a family energy system.

[0007] Figure 2 yes Figure 1 A schematic diagram of a portion of a home energy system.

[0008] Figure 3 It is used for inspection Figure 1 A flowchart illustrating the algorithm for the operational readiness status of certain components of a home energy system. Detailed Implementation

[0009] This document describes embodiments. However, it should be understood that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The drawings are not necessarily drawn to scale. Some features may be enlarged or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art.

[0010] The various features shown and described with reference to any of the accompanying drawings may be combined with features shown in one or more other drawings to produce embodiments not explicitly shown or described. The combinations of features shown provide representative embodiments for typical applications. However, for a particular application or implementation, various combinations and modifications of features consistent with the teachings of this disclosure may be desired.

[0011] This paper describes the verification of voltage in the Electric Vehicle Power Supply Equipment (EVSE) and the support devices in the combiner box dark-start battery configuration during power outages. The proposed strategy includes periodic testing that can be performed when the grid is supplying power to the home, ensuring that each system receives the required DC power, even during power outages. In the example, several steps are performed after entry conditions are met, which may include a grid-connected system, a power grid supplying power to the home, communication established between the combiner box and the EVSE, communication established to the cloud, and / or a predetermined number of days since the last dark-start battery check. The first step may involve disabling the combiner box's main switch-mode power supply (SMPS) and enabling the combiner box's dark-start battery SMPS, after which the combiner box sends a dark-start battery check signal to the EVSE. The EVSE disables its SMPS and consumes dark-start battery power via Power over Ethernet (PoE). The combiner box then checks its dark-start battery voltage / current, and the EVSE checks its dark-start battery voltage / current. If both tests pass, the test ends. This ensures that each system receives the necessary DC power during a power outage, and this is achieved by disabling the SMPS and enabling the dark start battery circuitry. Both the combiner box and the EVSE monitor their input voltage during testing. After a predetermined amount of time, the dark start battery circuitry is disabled, and the SMPS is enabled.

[0012] Combiner boxes are components in some home backup energy systems that connect various energy sources, such as solar panels, wind turbines, generators, and vehicles, to the grid. Their primary function is to combine the output from these multiple energy sources into a single electrical output. This combined output can then be routed to an inverter or central controller, simplifying the management of the various inputs.

[0013] Combiner boxes may be equipped with several components, including overcurrent protection devices (such as fuses or circuit breakers) to protect wiring and other components from potential overcurrents caused by faults or mismatches in panel outputs. Additionally, surge protection devices within these boxes help protect against voltage spikes typically caused by lightning strikes or grid interruptions. Disconnect switches are also included to allow manual disconnection of power sources for system maintenance or other checks. Furthermore, modern combiner boxes may incorporate voltage and current sensors in parallel at each input to facilitate monitoring and optimization of each power source's performance, thereby aiding in fault diagnosis and system management.

[0014] The combiner box controls the AC power flow from multiple AC sources (such as photovoltaic inverters, electric vehicles, and stationary battery inverters) to an AC bus, which can be tapped or powered by AC loads including home high-voltage energy storage devices or the power grid.

[0015] When integrated into a home energy system, a combiner box allows output from solar panels or other energy sources to be aggregated for use in home appliances, battery storage, or fed back into the grid. An external inverter, separate from the combiner box, manages the energy flow to and from the battery storage system. Combiner box aggregation allows for energy storage during periods of low usage and energy utilization during peak demand or low generation times. The combiner box also facilitates the integration of generators and vehicles into the grid as supplementary inputs, potentially optimizing energy use based on availability or economic considerations, such as using stored battery power during peak grid prices.

[0016] Systems equipped with grid-connected inverters can send excess electricity back to the public grid, generating credit or income for homeowners. These systems can also participate in demand response services, helping to stabilize the grid by adjusting the system's energy consumption or supplying stored energy during peak hours. Enhanced by IoT technology, modern combiner boxes can be integrated into larger energy management systems that optimize home energy use. Homeowners can monitor their energy systems in real time via smartphone apps or computer software, assessing everything from the output of individual solar panels to battery status and the overall efficiency of the system.

[0017] SMPS stands for Power Conversion Device. Unlike traditional linear power supplies that dissipate excess voltage as heat to control output, SMPS rapidly switch on and off to control the amount of energy delivered to the load, thereby minimizing energy loss. This switching action is managed by a semiconductor device (typically a transistor) that alternates between low-impedance and high-impedance states, thus effectively controlling the voltage and current delivered to the load.

[0018] The operation of an SMPS involves several stages. First, the AC mains voltage is rectified to generate high-voltage DC. Then, this high-voltage DC is converted to high-frequency AC through the switching action of transistors. A small transformer is then used to transform this high-frequency AC to the desired voltage level. After transformation, the AC is rectified again to produce a stable DC output. The output voltage is controlled by adjusting the duty cycle of the switching transistors, which is the ratio of the transistor's on-time to its off-time. This control is achieved through a feedback mechanism that continuously monitors the output and adjusts the switching accordingly to maintain a constant output voltage, regardless of changes in the input voltage or load conditions.

[0019] SMPS can adapt to a wide range of input voltages. The relatively fast response time of SMPS to changing load conditions and the ability of SMPS to provide features such as overvoltage protection, current limiting, and thermal shutdown further contribute to the robustness of SMPS.

[0020] The EVSE's function extends beyond simply supplying power; it also communicates with the electric vehicle to coordinate the charging process. This involves communication protocols that verify the integrity of electrical connections, identify the maximum current capacity of the electric vehicle's onboard charger, and ensure the vehicle is properly connected and ready to receive power before charging begins. The EVSE manages the power delivery to the vehicle, modulating the current and monitoring for connections in case of faults or sudden disconnections.

[0021] EVSE varies in the charging levels it offers, which are primarily categorized into three levels based on power output and charging speed. Level 1 charging is the slowest form, using a standard 120-volt AC outlet common in home settings. It delivers approximately 1.4kW of power and is typically used for overnight charging, providing about 4 to 5 miles of range per hour of charging. Level 2 charging uses a 240-volt AC supply, similar to those used for large household appliances. It significantly increases charging speed, providing about 15 to 70 miles of range per hour of charging, with power output ranging from 3kW to 22kW. The fastest type, Level 3, also known as DC fast charging, uses a direct current (DC) supply of up to 400 volts or higher, providing power levels of up to 50kW and up to 350kW in some facilities. This can charge an electric vehicle's battery to 80% capacity in as little as 20 minutes.

[0022] Some EVSEs feature integration with smart grid technologies, offering capabilities such as scheduled charging during off-peak hours, remote control and monitoring via smartphone apps, and integration with home energy management systems. This smart connectivity supports grid stability by allowing electric vehicles to be used as a grid resource. In vehicle-to-grid settings, electric vehicles can feed energy back into the grid, helping to balance supply and demand dynamics.

[0023] Some features in EVSE may include ground fault circuit interrupter protection and connectivity checks to ensure that the charger communicates with the vehicle before and during the charging process.

[0024] refer to Figure 1 Example home energy system 10 includes a combiner box 12, a main panel 14 associated with the home, solar panels 16, stationary batteries 18, a generator 20, an electric vehicle energy system (EVSE) 22, and an electric vehicle 24 including a traction battery and bidirectional power capability. The combiner box 12 is connected to a utility meter 26 of the power grid 28 and is connected between the main panel 14 and the solar panels 16, stationary batteries 18, and generator 20. The combiner box 12 can also be connected to the electric vehicle 24 via the EVSE 22. In this arrangement, the solar panels 16, stationary batteries 18, generator 20, and electric vehicle 24 are backup power sources for the home. The EVSE 22 and electric vehicle 24 can communicate with a mobile device 30 (e.g., a cellular phone) via cloud services or the like. When the power grid 28 becomes unavailable, the combiner box 12 is isolated from the power grid 28, communicates with the backup power sources for the home, and controls the AC power flow to support the home.

[0025] refer to Figure 2 The combiner box 12 includes a main SMPS 30, internal circuitry 32, a backup (or dark start) power supply 34 (e.g., a 12V battery), a backup (or dark start) SMPS 36, a controller including a microprocessor 38, and a communication module 40 (e.g., a Wi-Fi module). The EVSE 22 includes a main SMPS 42, internal circuitry 44, a backup (or dark start) SMPS 46, a controller including a microprocessor 48, and a communication module 50 (e.g., a Wi-Fi module). When power from the grid 28 is unavailable, the backup power supply 34 assists in starting certain components of the home energy system 10. When the electric vehicle 24 is absent and the grid 28 is unavailable, the backup power supply powers components of the combiner box 12 and the EVSE 22, for example.

[0026] When the EVSE 22 is electrically connected to the combiner box 12 and the electric vehicle 24, a continuous AC line 50 is established between the electric vehicle 24 and the power grid 28. The main SMPS 30 is electrically connected to the AC line 50. The main SMPS 30, internal circuitry 32, and backup SMPS 36 are electrically connected together. Backup power supply 34 and backup SMPS 36 are also electrically connected together. The microprocessor 38 communicates with the communication module 40 and can control components of the combiner box 12 via, for example, enable lines 52 and 54 associated with the main SMPS 30 and backup SMPS 36, respectively.

[0027] The main SMPS 42 is electrically connected to the AC line 50. The main SMPS 42, internal circuitry 44, and backup SMPS 46 are electrically connected together. The microprocessor 48 communicates with the communication module 50 and can control components of the EVSE 22 via, for example, enable lines 56 and 58 associated with the main SMPS 42 and backup SMPS 46, respectively.

[0028] The backup power supply 34 and backup SMPS 46 are connected via an Ethernet connection, enabling PoE power transfer between them. Additionally, microprocessors 38 and 48 are connected via a communication link.

[0029] refer to Figure 1 , Figure 2 and Figure 3 The correct operation of the backup power supply 34 and related components can be checked periodically. This can be performed, for example, when the power grid 28 is available and supplies power to the home; when communication between the combiner box 12 and the EVSE 22 is established; when communication between the EVSE 22, the electric vehicle 24 and the cloud is established; and / or when a predetermined period of time (e.g., 3 days, 7 days) has elapsed since the last operational check.

[0030] At operation 60, the main SMPS 30 is disabled by setting enable line 52 to '0', and the backup SMPS 36 is enabled by setting enable line 54 to '1'. At operation 62, the open-circuit voltage of the EVSE 22 is checked via voltage and / or current sensors associated with internal circuitry 32 and arranged in a known manner to sense such parameters. If the open-circuit voltage falls within a certain predefined range, the check passes. Otherwise, the check fails. At operation 64, combiner 12 conveys its intention to check its backup power supply 34 to the EVSE 22 via a communication link between microprocessors 38, 48. In response, at operation 66, the main SMPS 42 is disabled by setting enable line 56 to '0', the SMPS 46 is enabled by setting enable line 58 to '1', and the EVSE 22 consumes power from the backup power supply 34 via PoE. At operation 68, the voltage and ambient temperature of the backup power supply 34 are checked via voltage and temperature sensors associated with internal circuitry 32 and arranged in a known manner to sense such parameters. The current is also checked via a current sensor associated with internal circuitry 32 and arranged in a known manner to sense such parameters. If the voltage falls within a predefined range, the voltage check passes. Otherwise, the check fails, and a message is sent to mobile device 30 via communication module 40 and the cloud. If the temperature falls within a predefined range, the ambient temperature check passes. Otherwise, the check fails, and a message is sent to mobile device 30 via communication module 40 and the cloud. At operation 70, the voltage and ambient temperature from the backup power supply 34 are checked via voltage and temperature sensors associated with internal circuitry 44 and arranged in a known manner to sense such parameters. If the voltage falls within a predefined range (e.g., 7V to 16V), the voltage check passes. Otherwise, the check fails, and a message is sent to mobile device 30 via communication module 50 and the cloud. If the temperature falls within a predefined range, the ambient temperature check will pass. Otherwise, the check will fail, and a message can be sent to the mobile device 30 via communication module 50 and the cloud. At operation 72, the primary SMPS 30 is enabled by setting enable line 52 to '1', the backup SMPS 36 is disabled by setting enable line 54 to '0', and the combiner box 12 communicates the completion of its backup power 34 check to the EVSE 22 via the communication link between microprocessors 38 and 48. At operation 74, the primary SMPS 42 is enabled by setting enable line 56 to '1', and the backup SMPS 46 is disabled by setting enable line 58 to '0', thus ending the operation check. The EVSE 22 no longer consumes power from the backup power 34 via PoE.

[0031] The algorithms, methods, or processes disclosed herein may be delivered to or implemented by a computer, controller, or processing device (such as microprocessors 38, 48), which may include any dedicated electronic control unit or programmable electronic control unit. Similarly, the algorithms, methods, or processes may be stored in many forms as data and instructions executable by a computer or controller, including but not limited to information permanently stored on non-writable storage media such as read-only memory devices and information reproducibly stored on writable storage media such as optical discs, random access memory devices, or other magnetic and optical media. The algorithms, methods, or processes may also be implemented as software executable objects. Alternatively, suitable hardware components, such as application-specific integrated circuits, field-programmable gate arrays, state machines, or other hardware components or devices, or firmware, combinations of hardware and software components, may be used to embody the algorithms, methods, or processes, in whole or in part.

[0032] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms covered by the claims. Power converters other than SMPS, such as flyback converters, may be used. Technologies other than PoE may allow power flow between the combiner box and the EVSE, etc. Furthermore, the terms used in this specification are descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of these disclosed materials. For example, the terms "controller" and "multiple controllers" may be used interchangeably herein, as the functionality of a controller may be distributed across several controllers / modules, all of which may communicate via standard technologies.

[0033] As previously described, features of various embodiments can be combined to form other embodiments of the invention that may not be explicitly described or shown. While various embodiments may have been described as offering advantages or preferences over other embodiments or prior art implementations in terms of one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics may be compromised to achieve desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, strength, durability, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. Therefore, embodiments described as less desirable than other embodiments or prior art implementations in terms of one or more characteristics are not outside the scope of this disclosure and may be desirable for a particular application.

[0034] According to the present invention, a home energy system is provided, comprising: a combiner box configured to disable the main power converter of the combiner box, enable the backup power converter of the combiner box, and send a signal to the electric vehicle power supply equipment such that the main power converter of the electric vehicle power supply equipment is disabled, the backup power converter of the electric vehicle power supply equipment is enabled, and power from the combiner box configured to provide power to start the backup power supply of the home energy system when the main power is unavailable flows to the electric vehicle power supply equipment.

[0035] According to one embodiment, the combiner box is further configured to enable the main power converter of the combiner box and disable the backup power converter of the combiner box after the power flows to the electric vehicle power supply equipment.

[0036] According to one embodiment, the combiner box is further configured to send a signal to the electric vehicle power supply equipment after the power flows to the electric vehicle power supply equipment, such that the main power converter of the electric vehicle power supply equipment is enabled, the backup power converter of the electric vehicle power supply equipment is disabled, and the power from the backup power source of the combiner box no longer flows to the electric vehicle power supply equipment.

[0037] According to one embodiment, the power from the backup power source of the combiner box flows to the electric vehicle power supply equipment via Ethernet power supply.

[0038] According to one embodiment, the backup power source for the combiner box is a battery.

[0039] According to one embodiment, the combiner box is further configured to send a signal related to the voltage or current of the power supply.

[0040] According to one embodiment, the junction box is further configured to send a signal related to the ambient temperature.

[0041] According to one embodiment, the main power converter and the backup power converter of the combiner box are switch-mode power supplies.

[0042] According to one embodiment, the main power converter and the backup power converter of the electric vehicle power supply equipment are switch-mode power supplies.

[0043] According to the present invention, a method includes: in response to the occurrence of a predefined condition when grid power is available for a combiner box and the combiner box is connected to an electric vehicle power supply device, disabling the main switch mode power supply of the combiner box, enabling the standby switch mode power supply of the combiner box, and sending a signal to the electric vehicle power supply device such that the electric vehicle power supply device consumes power from the combiner box via Ethernet power supply, which is configured to provide power to start a battery of a home energy system including the combiner box when grid power is unavailable.

[0044] In one aspect of the invention, the method includes: sending the signal such that the main switch-mode power supply of the electric vehicle power supply equipment is disabled and the backup switch-mode power supply of the electric vehicle power supply equipment is enabled.

[0045] In one aspect of the invention, the method includes: after the electric vehicle power supply equipment consumes the power, sending another signal to the electric vehicle power supply equipment such that the main switch mode power supply of the electric vehicle power supply equipment is enabled and the standby switch mode power supply of the electric vehicle power supply equipment is disabled.

[0046] In one aspect of the invention, the method includes: sending a signal related to the voltage or current of the power.

[0047] In one aspect of the invention, the method includes: sending a signal related to ambient temperature.

[0048] According to the present invention, a combiner box is provided, comprising: a main switch mode power supply and a standby switch mode power supply; a battery configured to provide power to start a home energy system including the combiner box; and a microprocessor programmed to disable the main switch mode power supply, enable the standby switch mode power supply, and then supply power from the battery to the electric vehicle power supply when grid power is available for the combiner box and the combiner box is connected to an electric vehicle power supply device.

[0049] According to one embodiment, the microprocessor is further programmed to supply power via Power over Ethernet.

[0050] According to one embodiment, the microprocessor is further programmed to enable the main switch mode power supply and disable the standby switch mode power supply, provided that the parameters derived from the power supply are within a predefined range.

[0051] According to one embodiment, the battery is a 12V battery.

[0052] According to one embodiment, the microprocessor is further programmed to send signals regarding the voltage or current of the power.

[0053] According to one embodiment, the microprocessor is further programmed to send signals about the ambient temperature.

Claims

1. A home energy system comprising: A combiner box is configured to disable the main power converter of the combiner box, enable the backup power converter of the combiner box, and send a signal to the electric vehicle power supply equipment when grid power is available to the combiner box and the combiner box is connected to the electric vehicle power supply equipment, so that the main power converter of the electric vehicle power supply equipment is disabled, the backup power converter of the electric vehicle power supply equipment is enabled, and power from the backup power supply of the combiner box flows to the electric vehicle power supply equipment.

2. The home energy system of claim 1, wherein the combiner box is further configured to activate the main power converter of the combiner box and disable the backup power converter of the combiner box after the power flows to the electric vehicle power supply equipment.

3. The home energy system of claim 1, wherein the combiner box is further configured to send a signal to the electric vehicle power supply equipment after the power flows to the electric vehicle power supply equipment, such that the main power converter of the electric vehicle power supply equipment is enabled, the backup power converter of the electric vehicle power supply equipment is disabled, and the power from the backup power source of the combiner box no longer flows to the electric vehicle power supply equipment.

4. The home energy system of claim 1, wherein the power from the backup power source of the combiner box flows to the electric vehicle power supply via Ethernet power supply.

5. The home energy system of claim 1, wherein the backup power source of the combiner box is a battery.

6. The home energy system of claim 1, wherein the combiner box is further configured to send a voltage-related signal to the power.

7. The home energy system of claim 1, wherein the junction box is further configured to send a signal related to the ambient temperature.

8. The home energy system of claim 1, wherein the main power converter and the backup power converter of the combiner box are switch-mode power supplies.

9. The home energy system of claim 1, wherein the main power converter and the backup power converter of the electric vehicle power supply equipment are switch-mode power supplies.

10. A method comprising: In response to the occurrence of a predefined condition where grid power is available for the combiner box and the combiner box is connected to the electric vehicle power supply equipment, the main switch mode power supply of the combiner box is disabled, the standby switch mode power supply of the combiner box is enabled, and a signal is sent to the electric vehicle power supply equipment, causing the electric vehicle power supply equipment to consume power from the combiner box's battery via Ethernet power supply.

11. The method of claim 10, further comprising: The signal is sent to disable the main switch mode power supply of the electric vehicle power supply equipment and enable the backup switch mode power supply of the electric vehicle power supply equipment.

12. The method of claim 11, further comprising: After the electric vehicle power supply equipment consumes the power, another signal is sent to the electric vehicle power supply equipment to enable the main switch mode power supply of the electric vehicle power supply equipment and disable the standby switch mode power supply of the electric vehicle power supply equipment.

13. The method of claim 10, further comprising: Send a signal related to the voltage of the power.

14. The method of claim 10, further comprising: Sends signals related to the ambient temperature.

15. A junction box, comprising: Main switch mode power supply and standby switch mode power supply; Battery; as well as A microprocessor is programmed to disable the main switch mode power supply, enable the standby switch mode power supply, and then supply power from the battery to the electric vehicle power supply equipment when grid power is available for the combiner box and the combiner box is connected to the electric vehicle power supply equipment.

Images