Charging station for electric vehicles and cooled cable therefor

Abstract

FIELD: charging station.SUBSTANCE: group of inventions relates to a charging station for electric vehicles and a cooled charging cable. The charging station comprises a housing. A screen or indicator panel is placed on the housing. Inside the housing are located: a power connection and primary energy metering unit, a high-voltage voltage converter, a low-voltage redundant power supply, a digital charging station controller, a digital data processing and transmission system, a coolant storage system, a cooling system, a docking unit and secondary energy metering sensors, a cooled charging cable with a charging connector, and an automatic fire detection system. The cooling system is configured to circulate coolant in a closed loop through the cooled charging cable and the charging connector. The station comprises an automatic fire extinguishing system, and the coolant used is fluoroketone “ФК”-5-1-12, which is also the fire-extinguishing agent in the fire extinguishing system.EFFECT: increasing fire safety.10 cl, 1 dwg

Description

[0001] FIELD OF TECHNOLOGY

[0002] The invention relates to the field of electric transport and charging infrastructure, namely to devices for transmitting electrical energy, and can be used to charge batteries of passenger and freight electric vehicles.

[0003] STATE OF THE ART

[0004] The prototype used is a charging station according to patent RU 2674914C1, comprising a housing, power circuits, a control system, and a cooling device. In the prior art, the cooling device is located within the station housing and is designed to cool power electronic components, such as a voltage converter. Cooling is achieved using a circulating liquid that removes heat from heating elements within the station. This technical solution is aimed at maintaining the temperature of the charging station's internal components.

[0005] However, this prototype has several significant drawbacks. First, the cooling system does not extend to the charging cable and connector, which are critical components that heat up when transmitting high currents. This limits the maximum transmitted power and current, as the cable is susceptible to overheating without cooling. Second, the lack of forced cooling of the cable itself prevents the cable from becoming too large to handle the increased power requirements. Third, it does not support the use of a dielectric coolant, such as fluoroketone, which, in the claimed invention, enables a single cooling circuit for all power conductors and also serves as a fire extinguishing agent, thereby comprehensively improving fire safety.Thus, the prototype does not achieve the stated technical results in terms of increasing power to 1000 kW, reducing the weight and dimensions of the cable, and comprehensively improving safety.

[0006] DISCLOSURE OF THE INVENTION

[0007] The objective of the claimed invention is to increase the transmitted electrical power, reduce charging time, improve fire safety, and address the increasing size and weight of charging cables. This is achieved by providing forced cooling of the power conductors during the charging process.

[0008] The stated technical result is achieved by a cooling charging cable and a charging station for electric vehicles, comprising a housing containing a screen or display panel. The housing houses a power connection and primary energy metering unit, a high-voltage voltage converter, a low-voltage redundant power supply, a digital charging station controller, a digital data processing and transmission system, a coolant storage system, a cooling system, a docking unit, and secondary energy metering sensors. The station is equipped with a cooled charging cable and a charging port. The charging port contains an integrated microcontroller and a liquid crystal display. For safety, the station also includes an automatic fire detection and extinguishing system.

[0009] The cooled charging cable includes power conductors housed in a special hollow insulating sheath that ensures coolant circulation, control command conductors, and a temperature-sensitive cable for monitoring temperature along the cable, all enclosed in an outer sheath. The cable terminates in a charging connector containing an integrated microcontroller, liquid crystal display, temperature sensor, and, crucially, an exchange chamber. Electrical plugs in the connector provide connection between the power and control circuits. The special insulating sheath of the cable's power conductors is hermetically sealed to the exchange chamber on one end and to the charging station's cooling system via a connecting unit on the other, forming a closed circuit for coolant circulation.

[0010] The invention utilizes a cooling system that continuously circulates coolant in a closed circuit through the cooled charging cable and charging connector. Direct contact between the coolant and the power conductors removes excess heat generated by their ohmic resistance during high-current transmission. This significantly increases the transmitted current to 1000 A and, accordingly, the charging power to 1000 kW, without increasing or decreasing the cross-section of the conductors. The high-voltage converter provides two charging voltage ranges: the first ranges from 150 to 500 V, and the second from 500 to 1200 V.

[0011] The charging station is typically connected to a 380 / 400 V AC, 50 / 60 Hz power grid via a power connection and primary energy metering unit. This unit supplies power to the high-voltage voltage converter, low-voltage redundant power supply, and cooling system. The charging station's digital controller, display or indicator panel, digital data processing and transmission system, automatic fire detection system, and automatic fire extinguishing system (if applicable) are supplied by a low-voltage redundant power supply. Batteries are used to back up the low-voltage (usually 12 V or 24 V) power supply.

[0012] The charging station's digital controller ensures safe operation, manages internal systems, and controls charging session parameters for the proposed charging station. The digital data processing and transmission system handles registration, verification, billing, and transmits service information from the charging station's digital controller to a remote server. After receiving permission from the remote server, the charging session is opened.

[0013] The preferred coolant option is fluoroketone FK-5-1-12 (chemical formula CF3CF2C(O)CF(CF3)2), which has high dielectric properties, allowing the use of a single cooling circuit for all power conductors. Fluoroketone FK-5-1-12 has pronounced dielectric properties and can circulate in a single cooling circuit (without the need for separate cooling circuits for each power conductor). When using high-temperature superconductors in power conductors, a coolant with a corresponding low-temperature range is used, ensuring conditions for superconductivity. Additionally, this same fluoroketone can be used as a fire extinguishing agent in a fire extinguishing system. The coolant reserve for the cooling system and the fire extinguishing system (if applicable) is located in the coolant storage system.

[0014] The digital controller manages all station systems, including starting and stopping the cooling system, interacting with the charging vehicle via standard protocols such as OCPP or OCPI. OCPI, OCPP, or other protocols appropriate to the charging station infrastructure and the electric vehicle being charged are used to exchange service information and select the voltage and power range during the charging session. The digital data processing and transmission system provides communication with a remote server for authorization, billing, and emergency message transmission.

[0015] The power conductors of the cooled charging cable can be manufactured using both traditional materials, such as multi-strand copper or silver conductive cores with a cross-section of 16-300 mm², and high-temperature superconductors, including superconducting tapes. When using traditional materials, the current transmitted through such a cooled charging cable reaches 1000 A. When using superconductors, the cooling system maintains the coolant temperature within the range required for superconductivity, significantly increasing the device's efficiency. Coolant circulation can be organized in a single O-circuit for all conductors or in separate circuits for each pole.

[0016] BRIEF DESCRIPTION OF DRAWINGS

[0017] The invention is illustrated by a drawing presented in Figure 1 in the form of a general diagram.

[0018] The numbers on the figures indicate:

[0019] 1 - body,

[0020] 2 - screen or display panel,

[0021] 3 - power connection and primary energy metering unit,

[0022] 4 - high voltage voltage converter,

[0023] 5 - low voltage redundant power supply,

[0024] 6 - digital charging station controller,

[0025] 7 - digital data processing and transmission system,

[0026] 8 - refrigerant storage system,

[0027] 9 - cooling system,

[0028] 10 - docking unit and secondary energy metering sensors,

[0029] 11 - Cooled charging cable,

[0030] 12 - charging connector,

[0031] 13 - built-in microcontroller (in socket),

[0032] 14 - liquid crystal display (in connector),

[0033] 15 - Automatic fire detection system,

[0034] 16 - automatic fire extinguishing system,

[0035] 17 - special exchange chamber.

[0036] The red dotted lines show the data cable, the green dotted lines show the DC cable: 12V / 24V, the purple lines show the AC cable: 220V, the black lines show the AC cable: 220V / 380V / 400V, the black dotted lines show the AC / DC cable: 150-500V / 500-1200V, and the blue dotted lines with two dots show the refrigerant pipeline.

[0037] IMPLEMENTATION OF THE INVENTION

[0038] The system operates as follows. After connecting charging port 12 to the electric vehicle, the user is authorized through digital data processing and transmission system 7. Charging station digital controller 6, powered by low-voltage redundant power source 5, establishes communication with the vehicle using standard protocols. Via power connection and primary energy metering unit 3, the station receives power from a 380 / 400 V AC network with a frequency of 50 / 60 Hz, which is converted by high-voltage voltage converter 4 to the required charging level, which can be in one of two ranges: 150-500 V or 500-1200 V.

[0039] After authorization and connection establishment, digital controller 6 initiates the charging session. Information about the start of the process is displayed on the screen or display panel 2. Controller 6 gives the command to start cooling system 9. Cooling system 9 circulates the refrigerant stored in refrigerant storage system 8.

[0040] Cooling via the charging cable is accomplished as follows. Coolant flows from cooling system 9 through connection unit 10 into the charging cable 11 being cooled. Inside the cable, the coolant circulates through a special hollow insulating sheath, in direct contact with the power conductors. This effectively removes the heat generated by the conductors' ohmic resistance when transmitting currents up to 1000 A.

[0041] The heated coolant then enters the exchange chamber of charging connector 12, where additional heat exchange occurs. The coolant then returns to cooling system 9, forming a closed circulation loop. When using traditional materials such as multi-wire copper or silver cores, the cross-section of the power conductors ranges from 16 to 300 square mm. When using high-temperature superconductors, including tapes, the cooling system maintains a special low-temperature coolant regime necessary for superconductivity.

[0042] The integrated microcontroller 13 in the charging port 12 receives temperature data from a temperature sensor located in the port and from a temperature-sensitive cable running along the power conductors. It continuously monitors these temperature parameters and transmits the data to the liquid crystal display 14 for user information and to the digital controller 6 for processing. At the same time, the secondary energy metering sensors 10 transmit energy consumption data to the controller 6.

[0043] During the entire charging session, the automatic fire detection system 15, receiving power from the low-voltage source 5, monitors the state inside the housing 1. Fluoroketone FK-5-1-12 is used as a refrigerant and fire extinguishing agent, which, when the fire extinguishing system 16 is triggered, is supplied to the fire zone from the refrigerant storage system 8. In the event of an emergency, the system 15 generates a signal, according to which the digital controller 6 carries out an emergency power shutdown through the power connection unit 3, activates the automatic fire extinguishing system 16 and transmits an emergency message to the remote server through the digital system 7.

[0044] After charging is completed or interrupted by the user, the digital controller 6 stops the cooling system 9, the circulation of the refrigerant through the cooled charging cable 11 stops, and information about the end of the session and its results is displayed on the screen 2 and display 14.

Claims

1. A charging station for electric vehicles comprising a housing on which a screen or indicator panel is placed, wherein inside the housing there is a power connection and primary energy metering unit, a high-voltage voltage converter, a low-voltage redundant power source, a digital controller of the charging station, a digital data processing and transmission system, a coolant storage system, a cooling system, a docking unit and secondary energy metering sensors, a cooled charging cable with a charging connector, an automatic fire detection system, characterized in that the cooling system is designed with the possibility of circulating the coolant in a closed circuit through the cooled charging cable and the charging connector, wherein the station additionally contains an automatic fire extinguishing system, and fluoroketone FK-5-1-12 is used as a coolant, which is simultaneously a fire extinguishing agent in the fire extinguishing system.

2. The charging station according to paragraph 1, characterized in that the charging connector contains a built-in microcontroller and a liquid crystal display.

3. A charging station according to paragraph 1, characterized in that the high-voltage voltage converter provides two ranges of charging voltage: the first within 150-500 V, the second within 500-1200 V.

4. The charging station according to paragraph 1, characterized in that the digital controller is designed with the ability to interact via the OCPP or OCPI protocols.

5. A cooled charging cable containing power conductors and control command transmission conductors enclosed in an outer sheath, characterized in that the power conductors are placed in a special hollow insulating sheath that forms a channel for the circulation of a coolant, wherein the cable is terminated by a charging connector containing an exchange chamber, and the hollow insulating sheath is hermetically connected to the exchange chamber on one side and to the cooling system of the charging station through a docking unit on the other side, forming a closed circuit for the circulation of the coolant, and fluoroketone FK-5-1-12 is used as the coolant, which is simultaneously a fire extinguishing agent in the fire extinguishing system of the charging station.

6. A cooled charging cable according to paragraph 5, characterized in that the power conductors are made of multi-wire copper or silver conductive cores with a cross-section of 16-300 mm 2 .

7. A cooled charging cable according to paragraph 5, characterized in that the power conductors are made of a high-temperature superconducting material, including in the form of superconducting tapes.

8. A cooled charging cable according to paragraph 5, characterized in that the circulation of the coolant is organized along a single O-shaped circuit for all power conductors.

9. A cooled charging cable according to paragraph 5, characterized in that the circulation of the coolant is organized along separate circuits for each pole.

10. A cooled charging cable according to claim 5, characterized in that it further comprises a temperature-sensitive cable located along the power conductors for monitoring temperature, and the charging connector comprises a temperature sensor.

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