Control of individual and system-connected external wallboxes using dynamic load management and fuse box-internal charging modules with connected external pistol holders with hanging and standing devices

Abstract

The invention relates to a method for controlling individual as well as system-connected wallboxes by means of a true dynamic load management system, which enables control through the standard use of a wattmeter at the house connection and its use without an SMGW, regardless of the number of wallboxes installed in parallel, in which the intelligence is housed in the standard fuse box in the form of a 3-4TE module, which is connected to the pistol holder at the charging point via cable, wherein a forward-facing inverter module enables three-phase onboard controllers to charge at up to 11kW even with single-phase house connections.The invention also relates to a device for a movable hanging installation from the ceiling or a pedestal with up to 4 charging points, which is made possible by reducing the width of the charging point, and a test device that can be plugged in like a charging pistol, which allows the electrical testing of a charging module without changing the contacts for different measurements.

Description

State of the art

[0001] The use of 11kW wallboxes (boxes) is becoming increasingly important with every newly registered electric car. The Federal Ministry of Transport sometimes subsidizes them with tax money; it is estimated that in Germany alone, there will be approximately 8 million single-family homes needed by 2030, corresponding to half of the current single-family homes. In addition, there are the charging stations required for multi-family homes and apartment blocks; roughly speaking, one can estimate a share of 1 / 3 per group (single-family home / multi-family home / high-rise). Other users in the municipal sector include the police, city hall, government offices, etc., as well as private businesses (banks, insurance companies, hotels, etc.). While the homeowner installs the single box, multi-family homes and businesses require a cluster.

[0002] With increasing pressure to reduce CO2 emissions, half of today's electricity producers (nuclear power plants, coal, etc.) will be taken off the grid, making supply bottlenecks likely. Therefore, politicians want to give the distribution system operator (DSO) access to the wallbox via smart meters to prevent grid overloads. However, with current energy production methods and the usage curves according to Fig. 1 – which will not change – is a great advantage, i.e., not during office hours (charging point installation in the company), but at home in the garage (more than 40 million homes in Germany). Furthermore, each operator should be able to set individual pricing to increase the cost of charging during peak times or to reward nighttime charging. However, overloading can occur in the low-voltage range in the street or in the house if the charging current is not kept below the maximum load in real time, which constantly fluctuates due to primary consumers (stove, instantaneous water heater, etc.).

[0003] In one of its studies, Oliver Wyman assumes that the power grid could collapse if approximately 70% of the German car fleet is charged instantaneously (non-intelligent charging) and BEVs account for approximately one-third of the total. However, if almost all cars were charged intelligently, even with a 100% BEV share of the car fleet, the power grid would not need to be expanded.

[0004] This requires true dynamic load management (DLM) systems, which are currently far from standard in wallbox installations. Wattmeters from specialized third-party providers with middle-tier infrastructure often have to be connected, especially for multi-box systems. Regulated charging capacities are usually offered as "local dynamic load management," in which the household load is not measured, but rather a maximum power is fixed for charging all connected boxes. This is a dangerous system because the basic household consumption can rise unexpectedly, potentially triggering the fuse.

[0005] The wallboxes offered are housed in enclosures. A single wallbox can only be operated as an independent wallbox. Wallboxes are offered in combination as master and slave systems, where the master wallbox controls itself and the slave wallboxes with static or local dynamic load management.

[0006] Due to the size of the wallboxes, a hanging device (e.g. in pillar-free garages) is just as unthinkable as a narrow standing column that can serve up to four EVs simultaneously.

[0007] It's also unpleasant to expose computers, displays, and the entire control electronics of a box to the elements: insects, UV light, hail. The plasticizers can't maintain the sealing function for decades. Therefore, all the electronics shouldn't be housed in the case at all!

[0008] Currently, the DSO cannot access the wallboxes for remote control. The plan is to do this via a Smart Meter Gateway (SMGW), which would entail high usage costs for each wallbox owner, potentially €100 per year. An internet-based system (simple server solution) is not provided for by law. Complex hardware is preferred.

[0009] The electrical functionality test of the wallbox is currently a complicated and time-consuming process using an external measuring device that requires plug manipulation during the measurements. Object of this invention

[0010] Therefore, a method and devices are to be presented that makes the use of a wattmeter standard and enables its use without additional middle-tier hardware, theoretically independent of the number of wallboxes installed in parallel. This means that the constant measurement of the current household base load using an inexpensive wattmeter, compared to the household connection value, determines the electricity load available for charging and (provided unused electricity capacity is available) could intelligently charge at least 6 cars simultaneously without ever exceeding the maximum load of the household connection. This means that this is about true dynamic load management of the entire household connection, not a local one based exclusively on the installed boxes. Additional cars would be charged automatically when active charging processes were completed. The system could therefore theoretically register an infinite number of boxes in the system.In practice, the increasing cable lengths required make a very large number of boxes uneconomical.

[0011] The wallbox is designed to be individually suspended within the housing and operate independently in a star-shaped solution. Alternatively, the charging module can be removed from the housing and installed directly in the fuse box or a lockable switch cabinet like a fuse. Any Type A + 6mA DC fuse, the smart meter, and the residual current device are also installed in the switch cabinet. This means that the electronics are no longer located in the wallbox as usual, but in a central fuse box in the electrical room or garage. From there, only the power cables are led outside and connected to the charging cable and charging gun using a holder. This would reduce maintenance, repair, and insurance costs and ensure the more fail-safe system runs more smoothly. The charging gun holder allows for a hanging fixture for a charging device in parking spaces without columns in a larger garage.

[0012] A sensible approach would be to have a multi-channel system per circuit board, or a control system per channel connected directly to the contactor (relay), keeping wiring simple and short. Even better would be a solid-state relay (SSR), which, including CTs (current-measuring toroids) and RCMs (residual current monitoring devices), fits into a standardized 2-3 module housing (36-54 mm) on the DIN rail in the fuse box. This eliminates the need for additional installation in single-family homes, while multi-family homes or large garages with, for example, 100 spaces can install a standard fuse box (94 mm installation depth) or surface-mounted housing next to the existing one for the installation of, for example, 100 modules.

[0013] When using single-phase power, the module can charge three EVs simultaneously. If the EV can only charge on one phase (e.g., VW E-UP), the module should now supply 1x32A to the EV charge controller instead of 3x16A.

[0014] If the power is only available in single-phase form (1x48A), as is common in some countries, a 1ph>3ph inverter module should be able to divide the power into 3 phases so that three-phase controllers in the EVs allow charging up to 11kW.

[0015] In addition, the DSO should be able to control all LPs (charging ports) according to all reasonable rules depending on the cluster problem (street, region, etc.) (maximum load, per time, per day on weekdays and holidays, or in the case of special temperature requirements, heating in cold temperatures, cooling in hot temperatures, as well as in special situations such as television events, weather conditions such as no wind, no sun, etc.). The DSO will be able to reduce the charging power accordingly to avoid overloading the regional grid. For this purpose, it should also be possible to predict usage events in the server system based on collected usage data and to warn the DSO wallbox electricity supplier in advance via the system. Disclosure and description of the invention: Basic structure with essential features of the inventionThe solution to these problems is 1. to operate the wattmeter installed directly at the house connection in broadcast mode and, if necessary, to inform all parallel connected boxes simultaneously about the current connection load via a server, so that theoretically an infinite number of boxes can be easily integrated without a box having to register in the wattmeter system, and 2. For the purpose of protection against vandalism and natural forces, the conventional boxes are replaced by simple pistol holders provided with QR code stickers including a parking sensor in accordance with. Fig. 3, which only connect the power cable to the charging cable, and to design the bracket so slim that it can be used for pillar-free parking spaces in a garage on a movable device suspended from the ceiling in accordance with. Fig. 6 can be mounted and the charging module including the entire intelligence (=current control; CP's cable-dependent voltage level is calibrated during installation) can be located in the central fuse switch cabinet and communicated via app on the user side, and 3. to design the module for up to 22kW, in such a way that it can be charged either with 3x6A up to 16A-32A or each of the three phases that the module can handle can be used individually for single-phase charging, from 1×6-32A, and 4. single-phase current up to 48A is split into three phases in the inverter module, which is mounted in front of the wallbox, to charge with 3 × 16A and achieve a charging power of up to 11kW, and 5. to connect the wallboxes or charging modules to the server via OCPP via Websocket at least before each charging process in order to include any information from the DSO in the charging rules, and 6. to design the charging modules so that each wallbox consists of a TE 3-4 shaped module in accordance with. Fig. 4 and can therefore be installed directly in the fuse box to prevent theft, vandalism, material decomposition, insect infestation and higher insurance costs, alternatively the module can be installed in a wall box in accordance with. Fig. 5 can be installed, and can be operated individually or in the form of a star installation, and 7. to design the test module on one side as a charging gun plug for insertion into the gun holder and on the other side as a receiving plug for the charging gun ( Fig. 8 and Fig. 9), so that the charging gun can be simply plugged in and within the test module, the test electronics trigger the individual measuring processes via RFID tag in the holder and log the measurement data in the system, without the need for plug-in manipulation during the measurements, and 8. a hanging device (e.g. for pillarless garages) or a standing column that can serve up to four EVs simultaneously ( Fig. 6 and Fig. 7), to use

[0016] Advantageous embodiments are specified in the claims.

[0017] The solution according to the invention eliminates the disadvantages of the prior art and achieves the following advantages: 1. Real DLM with wattmeter (protecting the real house connection) without middle tier hardware for theoretically infinitely many parallel connectable wallboxes, without a box having to register in the wattmeter or middle tier system; 2. Vandal-proof and natural force-resistant system that simply connects the power / CP cables to the gun holder, with all the intelligence (power control) located in the central fuse control panel and the user communicating with the system via an app, which operates either through multi-channel control on a single board or has a control system per channel connected directly to the contactor (contactor, relay), making wiring simple and short; 3. SMGW-free system, which may also enable the DSO to precisely control the load of each box individually and / or per street, region, etc. and can take load limitations into account, e.g. according to the DSO's requirements, in order to avoid costly line expansion, in such a way that the box can react to the DSO's regional transformer situation by reducing the current and avoiding binary states (only on or off); 4. The module in 3-4TE design (e.g. for installation in the standard flush-mounted fuse box with 94MM depth) can be used for single-phase and three-phase connections. 5. The wallbox can also be used individually. It contains the removable charging module for a star-connected installation, for example, if the charging gun is to be connected directly to the fuse box to prevent theft, vandalism, material degradation, insect infestation, and the resulting higher insurance costs. 6. The gun holder is slightly wider than the loading gun and allows installation on a movable device suspended from the garage ceiling for up to four column-free parking spaces per device as well as 7. The gun holder allows for column mounting for up to four column-free parking spaces per device. 8. The test module can be used to test the functionality of a wallbox and log the results via the communication interface without having to reconnect the contacts for a measurement. The test adapter, which does not have a display or buttons / toggle switch, displays its data on the wallbox display and uses the wallbox's NFC function for any confirmations / start sequences. List of reference symbols:

[0018] Fig. 3 1 opening for cable from the charging module 2 grooves for cable hanging 3 Display 4 parking sensors 5 Mounting device for loading pistol 6 Opening cable outlet charging cable

[0019] Fig. 9 1 pistol holder 2 test adapters 3 loading pistol

Claims

[1] Method for controlling individual and system-connected external wallboxes using dynamic load management and fuse box-internal charging modules with connected external gun holders, with hanging and standing device characterized by that the wattmeter can be operated in broadcast mode, determines the currently available charging load by means of a controller and distributes it to all parallel connected boxes or supplies the boxes with power sequentially, so that theoretically an infinite number of boxes can be integrated without a box having to register in the wattmeter or a middle-tier system and the system would also run without server operation or the boxes or each charging line communicates with the server via OCPP via Websocket at least before each charging process in order to include any information from the DNB in ​​the charging rules, so that SMGW remains superfluous ( Fig. 2). [2] Device for controlling individual and system-connected external wallboxes by means of dynamic load management and fuse box-internal charging modules with connected external gun holders, with hanging and standing device characterized by that the said gun holder including parking sensor ( Fig. 3) said charging module detects a car parked in front of the parking space in order to indicate both any unauthorized vehicle parking as well as vehicle exit without a pistol connection to the vehicle in order to correct the "behavior error" so that the BEV is always connected to the charging system at least at the home parking space and recharges the battery to preferably 80% of its capacity. [3] Device for controlling individual and system-connected external wallboxes by means of dynamic load management and fuse box-internal charging modules with connected external gun holders, with hanging and standing device characterized by , that a. For the purpose of protection against vandalism and natural forces, the conventional wall boxes are replaced by simple pistol holders with QR code stickers, which only connect the power cable to the charging cable, or the said pistol holder is equipped with an RS485 module with display, for example, for the purpose of legal metrology compliance, communicates with the charging module via RS485 and makes the generated QR code scannable for simplified charging applications and displays the charging data, in particular the kWh consumed, and the entire intelligence (power control) takes place in the central fuse switch cabinet and the user communicates with the system via an app, whereby the RS485 display module with Wi-Fi function, if installed in the said pistol holder, can also offer a direct wireless connection between the system and the smartphone, and b. the system consists either of a multi-channel control on a board or a 2-3TE module that includes contactor, FI 6mA DC and 30mA AC as well as LS, AC-DC power supply and the entire control system and can be mounted on the 35mm standard DIN rails, so that the wiring is simple and short, and c. the module in 2-5TE design, preferably 3TE=54mm (preferably for installation in the standard flush-mounted fuse box with 94mm depth) ( Fig. 4) can be used for single-phase and three-phase connections or only single-phase connections or only three-phase connections, and said module system is preferably installed on the dummy socket in front of the parking space ( Fig.3) has a sensor that detects a parked car and preferably via the RS485 communication to the module and from there preferably via WiFi to the WiFi router preferably integrated in the module-accommodating housing, e.g. a fuse box, and further preferably via the Internet to the central server enables communication with, for example, the parking space manager and / or the parking space user in order to indicate both any unauthorized vehicle parking as well as vehicle leaving without a pistol connection to the vehicle, preferably via smartphone, so that the BEV is always connected to the charging system at least at the home parking space and recharges the battery to preferably 80% of its capacity. [4] Device for controlling individual and system-connected external wallboxes by means of dynamic load management and fuse box-internal charging modules with connected external gun holders, with hanging and standing device characterized bythat the charging module ( Fig. 4) in the form of a 2-3 HP module, which is installed directly on the DIN rail in the fuse box and is thus protected against theft, vandalism, material decomposition, insect infestation, and also to avoid higher insurance costs. It is designed to be operated as a standalone wallbox or used in a star installation. The charging module can also be installed in a wallbox housing ( Fig. 5). The charging gun is connected either directly to the charging module in the fuse box or to the wallbox. [5] Device for controlling individual and system-connected external wallboxes by means of dynamic load management and fuse box-internal charging modules with connected external gun holders, with hanging and standing device characterized bythat the slim shape of the charging gun holder is attached to a suspension device for up to four EVs, which allows deflections of up to 45° by means of a cardan joint, thus allowing the device to give way to the car driving against it. ( Fig. 6). [6] Device for controlling individual and system-connected external wallboxes by means of dynamic load management and fuse box-internal charging modules with connected external gun holders, with hanging and standing device characterized by that the slim shape of the charging gun holder on a column allows for up to four parking spaces per column. ( Fig. 7) [7] Device for controlling individual and system-connected external wallboxes by means of dynamic load management and fuse box-internal charging modules with connected external gun holders, with hanging and standing device characterized byBy plugging a test device into the gun holder and simultaneously plugging the charging gun into the test device, the electrical testing of the charging module and logging of the results on the server can be performed without having to replug the contacts for each measurement. A measurement is initiated, if necessary, by an RFID tag on the gun holder. Data is displayed on the wallbox display. ( Fig. 8 and Fig. 9)

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