Ev charging power station capable of off-grid operation, control system for ev charging power station and method of managing power sources of ev charging power station

Abstract

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

Description

6250-W50840 EV CHARGING POWER STATION CAPABLE OF OFF-GRID OPERATION, CONTROL SYSTEM FOR EV CHARGING POWER STATION AND METHOD OF MANAGING POWER SOURCES OF EV CHARGING POWER STATION BACKGROUND OF THE INVENTION 1. Field of the Invention

[0001] The present invention relates to an electric vehicle (EV) charging power station which is capable of off-grid operation, a control system for the EV charging power station, and a method of controlling and managing the power sources of an EV charging power station. 2. Discussion of Background Information

[0002] As the number of electric vehicles has increased significantly over the last few years EV charging is booming, growing rapidly year-by-year. Direct current (DC) fast charging at charging power stations becomes a real necessity for “on-the-go” quick recharging but requires the availability of high-power sources. However, there currently is a lack of high- power availability in many locations. There still are many locations with only a weak- powered electric grid, or none at all, especially (but not exclusively) in rural and more remote areas. Even if upgrades are theoretically available, it can take 18-24 months to set up a new charging infrastructure.

[0003] In view of the foregoing and the ever-increasing number of EVs on the roads there is an urgent need for charging power stations for EVs which can be placed even in areas where the grid is weak or not available at all. SUMMARY OF THE INVENTION

[0004] The present invention provides an EV charging power station power and energy source which comprises (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries for energy storage. The charging power station also comprises a connection to (iii) an electric grid. The charging power station further comprises a control system which is configured to control and manage the power sources present in the charging power station. In doing so, the control system takes into consideration one or more of (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 power6250-W50840 source, (d) the environmental impact of an available power source (carbon footprint, availability from renewable sources, etc.), (e) the current and / or predicted demand of energy at the one or more chargers, and (f) the current and / or desired EV charging speed.

[0005] In one embodiment of the charging power station, the control system takes into account at least two 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).

[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 power station comprises a connection to an electric grid (iii) and / or a connection to a photovoltaic installation (iv).

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

[0009] In one embodiment of the charging power station the control system causes the charging power station to operate (1) in a mode in which the one or more chargers charge one or more EVs with power from source (iii) and / or power from source (ii) but without power from source (i) and / or (2) in a mode in which the one or more chargers charge one or more EVs with power from source (ii) and / or source (iii) and / or source (iv) and / or source (v), and source (i) is activated only if a predicted demand of charging energy cannot be satisfied by the other available power sources alone, and / or (3) in a mode in which the one or more chargers charge one or more EVs with power from source (ii) and / or source (iii) and / or source (iv) and / or source(v) and, optionally, power from source (i), and the charging load is reduced if the current demand of charging energy cannot be satisfied by all of the available power sources.6250-W50840

[0010] In one embodiment of the charging power 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 they are not needed for charging one or more EVs.

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

[0012] Specific embodiments of the control system include all of those which are set forth above in connection with the charging station of the invention.

[0013] The present invention further provides a method of controlling and managing the power sources of an EV charging power station which comprises one or more EV chargers and, as power sources, (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries and, optionally, a connection to one or more of (iii) an electric grid, (iv) a photovoltaic installation or (v) a wind power installation. The method comprises controlling and managing the power sources while taking into consideration one or more of (a) the current availability of a (each) power source (i) to (v), (b) the power available from a (each) currently available power source, (c) the current price of power from an (each) available power source, (d) the environmental impact of an (each) available power source, (e) the current and / or predicted demand of charging energy at the one or more charging power stations, and (f) the current and / or desired EV charging speed.6250-W50840

[0014] Specific embodiments of the above method include those which are set forth above in connection with the charging power station of the invention. BRIEF DESCRIPTION OF THE DRAWING

[0015] The present invention is further described in the detailed description which follows, in reference to the accompanying drawing by way of a non-limiting example of an exemplary embodiment of the present invention. In the drawings: FIG. 1 schematically shows components of an exemplary charging power station of the invention. DETAILED DESCRIPTION OF EMBODIMENTS OF THE PRESENT INVENTION

[0016] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawing making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

[0017] As stated above, the present invention provides inter alia, an EV charging power station which comprises, as power sources, (i) one or more (e.g., 1, 2, 3, 4, 5, 6 or more) hydrogen-powered fuel cells and (ii) one or more (e.g., 1, 2, 3, 4, 5, 6 or more) batteries. Optionally (and preferably) the charging power station also comprises a connection to one or more of (iii) an electric grid, (iv) a photovoltaic installation or (v) a wind power installation. The charging power station further comprises a control system which is configured to control and manage the power sources. In doing so, the control system takes into account one or more of (a) the current availability of a (each) power source (i) to (v), (b) the power available from a (each) currently available power source, (c) the current price of power from a (each) available power source, (d) the environmental impact of an (each) available power source (carbon footprint, availability from renewable sources, etc.), (e) the current and / or predicted6250-W50840 demand of charging power at the one or more chargers, and (f) the available and / or desired EV charging speed.

[0018] In one embodiment of the charging power station, the control system takes into account at least two (e.g., 2, 3, 4, 5 or 6) 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).

[0019] The power source (i) may comprise or consist of one or more (e.g., 1, 2, 3, 4 or more) alkaline fuel cells and / or the power source (ii) may comprise or consist of one or more (e.g., 1, 2, 3, 4 or more) Lithium Iron Phosphate (LFP) batteries. Of course, other types of batteries such as nickel- cadmium (Ni-Cd), nickel metal hydride (Ni-MH), and lithium ion (Li-Ion) batteries can be used as well, as can be combinations of different types of batteries, although this is usually not preferred. The use of LFP batteries is preferred, inter alia because they are capable of high-speed charging and discharging and feature a higher power density, a lower discharge rate, lower heat generation and higher charging cycles than other types of batteries, usually with increased safety and resiliency.

[0020] The hydrogen and / or ammonia used for the one or more fuel cells is preferably green and / or blue hydrogen / ammonia, e.g., hydrogen formed by electrolysis of water with electricity generated by photovoltaic and / or wind installations.

[0021] If the charging power station comprises a connection to a photovoltaic installation (iv) the latter may be a part of the charging power station. For example, the photovoltaic installation may comprise solar panels on a roof which covers the charging stalls or even the entire charging power station or a part thereof. Of course, the photovoltaic installation may also be remote from the charging power station.

[0022] A connection to an electric grid (iii) is preferred but not absolutely necessary as the charging power station can charge EVs even without the availability of an electric grid, due to the presence / availability of power sources (i) and (ii) (and optionally, power sources (iv) and / or (v)). It will usually be preferred to connect the charging power station to the grid whenever a grid is available. In this case it may also be possible to feed excess energy, e.g.,6250-W50840 energy generated by the photovoltaic installation which is neither necessary for charging the one or more batteries (ii) nor for charging one or more EVs back to the grid and thereby receive a refund or credit from an electricity provider.

[0023] The charging power station will usually also comprise a storage system for the hydrogen which is the fuel for power source (i). The storage system may comprise, e.g., a number of hydrogen cylinders. Alternatively or additionally, the charging power station may be supplied with hydrogen via a pipeline. Alternatively or additionally, the charging power station may comprise a storage system (and / or be supplied by a pipeline) for ammonia, in this case in combination with a system which is capable of thermally decomposing ammonia into hydrogen and nitrogen.

[0024] The control and managing of the power sources (i) to (v) includes, inter alia, a determination as to which of the available power sources are to be employed in a pre-defined situation and for which purpose these power sources are to be employed (e.g., directly by providing energy to a charger or indirectly by charging the one or more batteries (ii)).

[0025] For example, in one embodiment of the charging power station, the control system causes the charging power station to operate (1) in a mode in which the one or more chargers charge one or more EVs with power from (iii) and / or power from (ii) but without power from (i) and / or (2) in a mode in which the one or more chargers charge one or more EVs with power from (ii) and / or (iii) and / or (iv) and / or (v), and (i) is activated only if a predicted demand of charging energy cannot be satisfied by the other available power sources alone, and / or (3) in a mode in which the one or more chargers charge one or more EVs with power from (ii) and / or (iii) and / or (iv) and / or (v) and, optionally, power from (i) and the charging load is reduced if the current demand of charging power cannot be satisfied by the available power sources.

[0026] Merely by way of example, the charging power station may operate in at least one of the following energy / power modes:

[0027] Sufficient Energy and Power Mode:6250-W50840 - EVs are being charged with energy from source (ii) and from source (iii), if available. - The one or more fuel cells (i) are not active as there is sufficient energy to meet the current (and predicted) demand. - Energy is not returned to the grid in any way.

[0028] Insufficient Energy Mode: - EVs are being charged with energy from source (ii) and from source (iii), if available (and optionally also with energy from (iv) and / or (v), if present). - The control system (Energy Management System) predicts that there will soon be a predefined “Insufficient-Energy-State” and signals the one or more fuel cells (i) to start up so they can provide additional energy once they are ready (after a short start- up period). - The one or more fuel cells (i) initiate a start sequence to be able to provide supplementary energy.

[0029] Insufficient Power Mode: - The control system determines that the power demand nears the point at which all available power sources will no longer be sufficient to satisfy the power demand. - The charge load of the chargers is reduced.

[0030] In one embodiment of the charging power station, if the 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 source (ii) while they are not needed for charging one or more EVs. For example, the control system may cause one or more of power sources (iii) to (v), if available, to recharge source (ii) at least partially while sources (i) to (v) are not needed for charging one or more EVs. In this regard, it is to be noted that power from source (i) is frequently more expensive than power from sources (iii), (iv) or (v), for example due to the fact that (compressed) hydrogen (or ammonia) has to be transported to the site of the charging power station (usually by trucks) and the transportation and logistics costs associated therewith. Keeping the one or more batteries (ii) fully or almost fully charged whenever possible and charging the one or more batteries with power from the least6250-W50840 expensive available power source whenever possible is one of the ways to increase (improve) the economics of the charging power station.

[0031] Accordingly, it will often be most cost-effective to avoid the use of power source (i), if possible, and to employ power sources (iii) and / or (iv) and / or (v). Power source (ii) can provide virtually instant power if power sources (iii) to (v) are not available or not sufficient to satisfy the current power demand. Power source (i) is often best used for providing back- up power if the available power sources (ii) to (v) together are not sufficient to satisfy the current charging power demand.

[0032] It is to be taken into account here that power source (i) is usually not available instantaneously as it requires some time for start-up. In view thereof, it is advantageous that the charging power station has the ability to predict the power demand based on predetermined time profiles such as, e.g., 24 h (daily) and 168 h (weekly) profiles using (1) the predicted availability of power (especially regarding sources (iv) and (v), but also with respect to source (iii)) and (2) the predicted site consumption (especially based on EV charging patterns, but optionally also as back-up for critical assets such as hospitals, first responders, POS teller machines, IT, etc.).

[0033] Fig. 1 is a schematic representation of an exemplary charging power station for six chargers according to the invention. Each of the chargers may, for example, provide up to 75 kW (scalable from 25 kW to 75 kW, depending on, e.g., the number of chargers in use).

[0034] The abbreviations shown in Fig. 1 have the following meaning: ENM Electric Network Manager EMS Energy Management System SCADA Supervisory Control And Data Acquisition NMS Network Management System PV Photovoltaic Installation BESS Battery Energy Storage System PCS Power Conversion System6250-W50840

[0035] As can be taken from Fig. 1, the charging power station comprises four hydrogen- powered alkaline fuel cells, each of which provides 48V DC and 5 kW (in parallel, total 20 kW). The output voltage of each fuel cell can be increased up to, e.g., 700V DC, for example by using DC / DC converters. The hydrogen for the fuel cells can be stored, e.g., in 64 (easily replaceable) gas cylinders. A typical bundle of 64 50L@300 Bar cylinders will provide an energy storage of 920kWh. The system is scalable in that more than four fuel cells, e.g., five, six or more fuel cells, may be employed. The number of fuel cells and battery energy storage generally increases with the number of chargers present in the charging power station. A changeover system which manages the hydrogen flow between the bundle and makes an automatic call for replacement cylinders when needed may also be provided.

[0036] In the exemplified embodiment the power source (ii) takes the form of several LFP batteries with a total base storage of 372.2 kWh. This Battery Energy Storage System (BESS) allows storage of excess power from other power sources (grid, photovoltaic installation and / or fuel cells) and uses the excess power per a defined logic of operation.

[0037] A grid connectivity element using a Power Conversion System (PCS) allows the charging power station to connect to the grid whenever a grid is available. This allows providing 180 kW to 350 kW. This also supports the customer in selling excess power back to the grid and operating the charging power station as a peak-shaving support.

[0038] A PV connection in the main panel allows the charging power station to add additional boosters as needed to handle PV installations. The coupling (DC or AC) will be defined per existing site arrangements.

[0039] The main Energy Management System (EMS) control unit manages and controls the charging power station components and power sources to allow a maximum balance and efficiency while prioritizing the different power sources. It can also be connected to any standard external monitoring system.

[0040] To sum up, the instant charging power station may offer one or more of the following features / advantages:6250-W50840 • Ensuring maximum power availability for fast DC chargers, even when the grid is weak or not available. • Controlling and activating multiple power sources (grid, PV, battery, wind) and local generation of power using fuel cells.•Planning and predicting the availability of energy o Predicting estimated requirements: weekday, weekend, seasonal o Predicting estimated generation: PV radiation, wind, grid availability o Preparing energy ahead-of-time when charger is booked by driver. o Predicting energy costs. • Software for: o Ensuring power availability ahead-of-time (generating and storing energy). Ahead-of-time = pre-booking or site-prediction. o Techno-economic power allocation (variable grid pricing, power generation costs). o Dynamic pricing of energy to end-customers, based on current cost of energy production and availability. o Connection to CPMS (Charge Point Management System) to: ^ DLM (Dynamic Load Management) of the chargers, for high frequency update of the power available for all chargers (when there is not enough power, DLM spreads it across the active chargers). ^ Reading charger usage information to predict station’s usage patterns. ^ Reading booking information. o Managing multiple battery banks in different C-rated banks (0.5 to 4C) and capacitors. This enables economical operation of ultra-fast chargers for high- power and industrial EVs.

Claims

6250-W50840 WHAT IS CLAIMED IS:

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

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

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

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

5. The charging power station of any one of claims 1 to 4, wherein (ii) comprises one or more Lithium Iron Phosphate (LFP) batteries.

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

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

8. The charging power station of any one of claims 1 to 6, wherein the charging power station comprises a connection to at least (iii) and / or (iv).6250-W50840 9. The charging power station of any one of claims 1 to 8, wherein the charging power station further comprises a hydrogen storage unit for (i).

10. The charging power station of any one of claims 1 to 9, wherein the control system is capable of causing the charging power station to operate in a mode in which the one or more chargers charge one or more EVs with power from (iii) and / or power from (ii) but without power from (i).

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

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

13. The charging power station of 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) while they are not needed for charging one or more EVs.

14. The charging power station of 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), if available, to recharge (ii) at least partially while (i) to (v) are not needed for charging one or more EVs.

15. A control system for an EV charging power station which comprises, as power sources, (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries and, optionally, a connection to one or more of (iii) an electric grid, (iv) a photovoltaic installation6250-W50840 or (v) a wind power installation, wherein the control system is configured to control and manage the power sources and takes into account one or more of (a) current availability of a power source (i) to (v), (b) power available from a currently available power source, (c) current price of power from an available power source, (d) environmental impact of an available power source, (e) current and / or predicted demand of charging energy at the one or more charging power stations, and (f) 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. The control system of any one of claims 15 to 17, wherein the control system is capable of causing the charging power station to operate in a mode in which the one or more chargers charge one or more EVs with power from (iii) and / or power from (ii) but without power from (i).

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

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

21. The control system of 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 remaining6250-W50840 power sources to at least partially recharge (ii) while they are not needed for charging one or more EVs.

22. The control system of 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), if available, to recharge (ii) at least partially while (iii) to (v) are not needed for charging one or more EVs.

23. A method of controlling and managing the power sources of an EV charging power station which comprises one or more EV chargers and, as power sources, (i) one or more hydrogen-powered fuel cells and (ii) one or more batteries and, optionally, a connection to one or more of (iii) an electric grid, (iv) a photovoltaic installation or (v) a wind power installation, wherein the method comprises controlling and managing the power sources while taking into account one or more of (a) a current availability of a power source (i) to (v), (b) power available from a currently available power source, (c) current price of power from an available power source, (d) environmental impact of an available power source, (e) current and / or predicted demand of charging energy at the one or more charging power stations, and (f) 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 power station is caused to operate in a mode in which the one or more chargers charge one or more EVs with power from (iii) and / or power from (ii) but without power from (i).

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

28. The method of any one of claims 23 to 27, wherein the charging power station is caused to operate in a mode in which the one or more chargers charge one or more EVs with6250-W50840 power from (ii) and / or (iii) and / or (iv) and / or (v) and, optionally, power from (i) and the charge load is reduced if the current demand of charging energy cannot be satisfied 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 they are not needed for charging one or more EVs.

30. The method of any one of claims 23 to 29, wherein, if (ii) is at least partially discharged, one or more of (iii) to (v), if available, are caused to recharge (ii) at least partially while (iii) to (v) are not needed for charging one or more EVs.

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