Electric vehicle charging apparatus

Abstract

According to an embodiment, provided is an electric vehicle charging apparatus comprising: a communication unit that receives detection data from a sensor disposed in a power module of a charger; a first processing unit that determines whether the power module is abnormal by using first detection data and temporarily suspends the operation of the power module if an abnormality is determined to have occurred in the power module; and a second processing unit that determines whether a failure has occurred in the power module by using second detection data and maintains the power module in a suspended state if a failure is determined to have occurred in the power module.

Description

electric vehicle charging device

[0001] The embodiment relates to an electric vehicle charging device.

[0002] Technology for detecting and diagnosing failures in power modules of electric vehicle charging devices is crucial for ensuring the safety and reliability of power conversion devices. A power module failure can impact the entire electric vehicle charging system, and in severe cases, can damage the battery or vehicle electronics.

[0003] When a failure occurs in a power module of an existing electric vehicle charging device, the charging device transmits a failure status to the charging device operating system via communication. Because the charging device operating system cannot accurately determine the power module's failure status, it determines the power module's operation based on the failure mode. In some failure modes, the charging device power module's operation is halted until external confirmation is obtained.

[0004] However, if the charging device power module is not working, there is a problem that the power required to operate the charging device is insufficient, which increases the charging time for electric vehicle charging customers.

[0005] In addition, existing power modules have various failure types, and the judgment on these is performed by the charger operation system, making it difficult to make an accurate judgment on these.

[0006] The technical problem to be achieved by the present invention is to provide an electric vehicle charging device capable of performing fault diagnosis on the power module itself.

[0007] In addition, the present invention provides an electric vehicle charging device capable of controlling the operation of a power module based on the results of a fault diagnosis.

[0008] In addition, the present invention provides an electric vehicle charging device capable of reducing the load on a charger operating system that manages multiple charging devices.

[0009] In addition, the purpose is to provide an electric vehicle charging device that can improve the operating efficiency of the charging device.

[0010] According to an embodiment, an electric vehicle charging device is provided, including: a communication unit that receives detection data from a sensor disposed in a charger power module; a first processing unit that determines whether the power module is abnormal using first detection data, and temporarily suspends the operation of the power module if it is determined that an abnormality has occurred in the power module; and a second processing unit that determines whether a failure has occurred in the power module using second detection data, and maintains the power module in a stopped state if it is determined that a failure has occurred in the power module.

[0011] The above sensing data may include temperature data, voltage and current data, vibration and noise data, and insulation resistance data.

[0012] The second processing unit can count the number of times an abnormality occurs in the power module using the second detection data collected over a predetermined period of time.

[0013] The above second processing unit can determine that a failure has occurred in the power module if the number of occurrences of the above abnormality exceeds a preset number of times.

[0014] The second processing unit can release the power module from the pause state if the number of occurrences of the abnormality does not exceed a preset number of occurrences.

[0015] The above communication unit can transmit a notification message to the charger operating system when it is determined that a failure has occurred in the power module.

[0016] The above second processing unit can determine the abnormal type of the power module.

[0017] The second processing unit may determine that a failure has occurred in the power module if the number of occurrences of the same abnormality type exceeds a preset number.

[0018] The second processing unit can release the power module from the pause state if the number of occurrences of the same abnormality type does not exceed a preset number of times.

[0019] An electric vehicle charging device according to an embodiment can perform fault diagnosis on the power module itself.

[0020] Additionally, the operation of the power module can be controlled based on the fault diagnosis results.

[0021] Additionally, it can reduce the load on the charger operating system that manages multiple charging devices.

[0022] Additionally, the operating efficiency of the charging device can be improved.

[0023] Figure 1 is a conceptual diagram of an electric vehicle charging device according to an embodiment.

[0024] Figure 2 is a drawing for explaining a power module according to an embodiment.

[0025] FIG. 3 is a drawing for explaining the operation of an electric vehicle charging device according to an embodiment.

[0026] Figures 4 and 5 are operation flowcharts of an electric vehicle charging device according to an embodiment.

[0027] Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the attached drawings.

[0028] However, the technical idea of ​​the present invention is not limited to some of the embodiments described, but can be implemented in various different forms, and within the scope of the technical idea of ​​the present invention, one or more of the components between the embodiments can be selectively combined or substituted for use.

[0029] In addition, terms (including technical and scientific terms) used in the embodiments of the present invention may be interpreted as having a meaning that can be generally understood by a person of ordinary skill in the technical field to which the present invention belongs, unless explicitly and specifically defined and described, and terms that are commonly used, such as terms defined in a dictionary, may be interpreted in consideration of the contextual meaning of the relevant technology.

[0030] Additionally, the terms used in the embodiments of the present invention are intended to describe the embodiments and are not intended to limit the present invention.

[0031] In this specification, the singular may also include the plural unless specifically stated otherwise in the phrase, and when it is described as “A and / or at least one (or more) of B, C”, it may include one or more of all combinations that can be combined with A, B, C.

[0032] Additionally, in describing components of embodiments of the present invention, terms such as first, second, A, B, (a), (b), etc. may be used.

[0033] These terms are intended only to distinguish one component from another, and are not intended to limit the nature, order, or sequence of the component.

[0034] And, when a component is described as being 'connected', 'coupled' or 'connected' to another component, it may include not only cases where the component is directly connected, coupled or connected to the other component, but also cases where the component is 'connected', 'coupled' or 'connected' by another component between the component and the other component.

[0035] Additionally, when described as being formed or arranged "above or below" each component, "above" or "below" includes not only cases where the two components are in direct contact with each other, but also cases where one or more other components are formed or arranged between the two components. Furthermore, when expressed as "above" or "below", it can include the meaning of a downward direction as well as an upward direction based on one component.

[0036] Hereinafter, embodiments will be described in detail with reference to the attached drawings. Regardless of the drawing numbers, identical or corresponding components are given the same reference numbers, and redundant descriptions thereof will be omitted.

[0037] Figure 1 is a conceptual diagram of an electric vehicle charging device according to an embodiment, and Figure 2 is a block diagram of the configuration of an electric vehicle charging device according to an embodiment.

[0038] Referring to FIGS. 1 and 2, an electric vehicle charging device (100) according to an embodiment is a device that connects to a power outlet installed in an apartment or house, as well as a public place or public building, through a power outlet connection connector (C) formed on the outside, and supplies power supplied from the power outlet to an electric vehicle (200) connected to the electric vehicle (200) connection connector (C) to charge a battery.

[0039] An electric vehicle charging device (100) receives a charging control signal from an external charger operating system (300), switches the power connection between a power outlet and an electric vehicle (200) according to the received control signal, and supplies AC commercial power applied through the power outlet to the electric vehicle (200).

[0040] An electric vehicle charging device (100) may include a communication unit (110), a power module (120), a processor (130), a display unit (140), a user interface unit (150), and a memory (160).

[0041] Additionally, the electric vehicle charging device (100) may be equipped with a connector (C) for connection to an electric vehicle (200).

[0042] The communication unit (110) can transmit and receive data by communicating with a user terminal (400) or charger operating system (300) possessed by an electric vehicle (200) driver.

[0043] The power module (120) can supply commercial power supplied from a power outlet to the electric vehicle (200) according to the switching of the processor (130).

[0044] The power module (120) can be configured to include a rectifier, an AC-DC converter, a DC-DC converter, etc., and can rectify commercial power supplied from a power outlet through the rectifier and then convert it into DC power used in an electric vehicle (200) through the AC-DC converter and the DC-DC converter.

[0045] The power module (120) converts AC power supplied from a power outlet into DC power used by the electric vehicle (200) when the electric vehicle (200) uses DC power and supplies it. When the electric vehicle (200) uses AC power, the power can be supplied to the electric vehicle (200) as is without any additional power conversion.

[0046] The memory (160) stores a program and various data for controlling the charging device, and can load the program or read or write data at the request of the processor (130).

[0047] The processor (130) can perform overall control of the charging device. The processor (130) can be configured to execute programs and instructions stored in the memory (160).

[0048] The processor (130) can control the power connection between the power module (120) and the electric vehicle (200) to be switched according to the charging station operating system or operation mode, so that power is supplied from the power module (120) to the electric vehicle (200) and charging is performed.

[0049] The processor (130) can control whether to supply power to the electric vehicle (200) through the power module (120). The electric vehicle (200) charging device can additionally include a protection circuit that blocks the connection between the power module (120) and the electric vehicle (200) when overcurrent, overvoltage, or overcharging occurs.

[0050] The processor (130) can calculate the amount of charging power supplied from the power module (120) to the electric vehicle (200). For example, the processor (130) can calculate the amount of power by calculating the product of the current supplied to the electric vehicle (200) and the charging voltage.

[0051] When charging is complete, the processor (130) can transmit the calculated charging power amount to the user terminal through the communication unit (110), thereby allowing the user to check the charging power amount compared to the charging cost paid.

[0052] The processor (130) may include a first processing unit (131) and a second processing unit (132).

[0053] The display unit (140) may be provided on the front of the electric vehicle charging device (100) and may be composed of an LED, LCD, etc., and may display information on the operating status of the electric vehicle charging device (100). In addition, the display unit (140) may be composed of a touch screen capable of detecting input, and may receive a user's request to instruct the charging device.

[0054] The user interface unit (150) may be configured as a hard type interface provided at a predetermined location outside the charging device, or as a soft type interface that can be touched on the display unit (140) to receive various requests related to the operation of the charging device.

[0055] Figure 3 is a drawing for explaining a power module according to an embodiment.

[0056] The power module (120) is a key component that performs power conversion to efficiently charge an electric vehicle battery. Electric vehicle charging devices require a complex power conversion process to ensure charging speed, efficiency, and stability. During this process, the power module (120) can convert input power (AC or DC) into voltage and current suitable for the vehicle's battery.

[0057] The power module (120) can perform multiple power conversion stages and may include an AC-DC converter (121), a PFC circuit (122), a DC-DC converter (123), and an output filter (124).

[0058] The AC-DC converter (121) is a rectifier that can perform an operation of converting AC power input to the charging device (100) into DC power. The AC-DC converter (121) can convert AC voltage into DC voltage using a diode bridge or an active rectification circuit. Active rectification can generally provide higher efficiency.

[0059] A Power Factor Correction (PFC) circuit (122) can improve power factor, thereby increasing power efficiency in the power grid and reducing electromagnetic interference (EMI). The PFC circuit (122) can reduce power loss and minimize impact on the power grid by matching the input current waveform to the AC power voltage waveform.

[0060] The DC-DC converter (123) can convert the rectified DC voltage into a voltage and current suitable for the battery of an electric vehicle. The DC-DC converter (123) can regulate the DC voltage using a CLLC resonant converter, an LLC resonant converter, or a simple buck converter. The CLLC resonant converter is particularly high in efficiency and low EMI, making it frequently used in electric vehicle charging devices.

[0061] The output filter (124) can remove ripple voltage from the output of the DC-DC converter (123) and provide stable DC power, thereby improving battery protection and charging efficiency. The output filter (124) can reduce voltage ripple and generate pure DC power using an LC filter (inductor and capacitor).

[0062] The power module (120) can process power in the following steps.

[0063] First, AC power input to the charging device (100) can be converted into DC power by an AC-DC converter (121). In this process, a PFC circuit (122) can be used to improve the power factor. This can optimize power usage from the power grid and reduce power loss.

[0064] The rectified DC voltage can be converted into a voltage suitable for the battery of an electric vehicle in a DC-DC converter (123). At this stage, voltage and current control is very important, and the voltage and current can be controlled in real time according to the battery's state of charge by a processor (130).

[0065] The converted DC voltage can be stabilized by passing through an output filter (124). The output filter (124) can remove voltage ripple and noise to provide DC power to the battery.

[0066] The processor (130) manages the entire charging process and can adjust the charging voltage and current according to the battery condition. This prevents overcharging, overheating, or other damage to the battery.

[0067] Through this process, the power module (120) can convert AC or DC power into the power required for the electric vehicle battery with minimal loss. Furthermore, it can supply a constant and stable power to the electric vehicle battery, thereby increasing charging efficiency and extending battery life.

[0068] Additionally, it effectively dissipates heat generated during the charging process, maintaining module performance and stability. Furthermore, it detects overvoltage, overcurrent, and overheating to protect the charging system and ensure safe charging.

[0069] An electric vehicle charging device according to an embodiment can collect information through a sensor mounted on a power module (120), analyze the collected information to analyze an abnormal state or a failure state of the power module (120), and control the operation of the power module (120) or transmit the analyzed result to a charger operating system (300).

[0070] The communication unit (110) can receive detection data from a sensor placed in the charger power module (120).

[0071] In an embodiment, a sensor may refer to a device mounted at a specific location on the power module (120) to collect various data regarding the operation of the power module (120) or the surrounding environment. For example, the sensor may include a temperature sensor, a current sensor, a vibration sensor, a noise sensor, a resistance sensor, etc. Each sensor may be mounted at a different location on the power module (120) and independently generate sensing data.

[0072] For example, a sensor that monitors the temperature of a power element (e.g., IGBT, MOSFET) in real time may be mounted inside the power module (120).

[0073] For example, voltage and current sensors may be installed at the input and output terminals of the power module (120) to detect the voltage and current input and output from the power module (120).

[0074] For example, a vibration sensor or microphone may be installed inside the power module (120) to detect vibration or noise generated from the power module (120).

[0075] For example, a sensor that monitors the insulation status and detects insulation resistance may be installed inside the power module (120).

[0076] In an embodiment, the sensing data generated through the sensor may include temperature data, voltage and current data, vibration and noise data, and insulation resistance data.

[0077] Additionally, if the communication unit (110) determines that a failure has occurred in the power module (120), it may transmit a notification message to the charger operating system (300). The notification message may include information on the type and status of the failure that has occurred in the power module (120). In addition, the notification message may include information indicating that the power module (120) requires replacement or repair.

[0078] The first processing unit (131) uses the first detection data to determine whether there is an abnormality in the power module (120), and if it is determined that there is an abnormality in the power module (120), the operation of the power module (120) can be temporarily stopped.

[0079] The first detection data may refer to detection data collected when the power module (120) is in normal operation or standby state. The first detection data may include at least one of temperature data, voltage and current data, vibration and noise data, and insulation resistance data.

[0080] For example, the first processing unit (131) can use temperature data to determine whether the power module (120) is abnormal. The first processing unit (131) can determine that an abnormality has occurred if the temperature of the temperature data exceeds a certain threshold. The first processing unit (131) can detect an abnormal temperature increase pattern through continuous temperature data analysis and determine an abnormal type of problem such as a problem in the cooling system or thermal overload of the power element.

[0081] For example, the first processing unit (131) can determine whether the power module (120) is abnormal using current and voltage data. The first processing unit (131) can monitor the power flow in real time using data from voltage and current sensors installed at the input and output terminals of the power module (120). The first processing unit (131) can detect a failure such as overvoltage, undervoltage, overcurrent, or short circuit when the voltage or current deviates from the expected range. The first processing unit (131) can detect abnormal current spikes, voltage drops, or excessive power consumption on the voltage and current data to determine the type of abnormality such as damage to an element, a short circuit in a circuit, or poor contact.

[0082] Alternatively, the first processing unit (131) can analyze the current and voltage waveforms of the power module (120) to determine whether there is an abnormality. The first processing unit (131) can compare the waveforms of the collected current and voltage data with waveforms in a normal state to detect abnormal changes. For example, abnormal waveforms may be generated due to increased switching noise, asymmetrical waveforms, or increased power ripple. The first processing unit (131) can determine the type of abnormality, such as a failure in a specific switching element, a problem with a resonant circuit, or a deterioration in the performance of a filter element, through waveform analysis.

[0083] Alternatively, the first processing unit (131) can determine whether there is an abnormality using vibration and noise data. The first processing unit (131) can detect the occurrence of an abnormality by analyzing mechanical vibration or noise generated from the power module (120) using vibration and noise data. When an abnormality occurs inside the power module (120), abnormal vibration or noise may be generated. For example, a problem with the cooling fan or a hum generated from the core of the transformer may be signs of such a failure. The first processing unit (131) can detect such abnormal signals through a vibration sensor or microphone and determine a problem with the motor or fan, a type of transformer abnormality, etc.

[0084] Alternatively, the first processing unit (131) can use insulation resistance data to determine whether there is an abnormality. The first processing unit (131) can monitor the insulation status inside the power module (120) to check whether the insulation resistance is within the allowable range. If the insulation resistance decreases, the leakage current increases, which may cause an abnormality, and if the insulation resistance decreases, an electrical insulation problem may be detected. The first processing unit (131) can periodically measure the insulation resistance to diagnose aging or damage of the insulator at an early stage and determine the type of abnormality, such as leakage current or electrical insulation.

[0085] Alternatively, the first processing unit (131) can continuously monitor the status of the power module (120) and predict failures by utilizing machine learning and AI algorithms. The first processing unit (131) can analyze operating patterns that deviate from normal conditions based on big data to determine the occurrence of abnormalities. The AI ​​algorithm of the first processing unit (131) can detect abnormal behavior and infer the type of abnormality by comparing learned patterns with real-time data.

[0086] If the first processing unit (131) determines that an abnormality has occurred in the power module (120), it can temporarily stop the operation of the power module (120) and output information indicating that an abnormality has occurred and information regarding the type of abnormality. The output information can be transmitted to the charging station operation system via the communication unit (110).

[0087] The second processing unit (132) may include a second processing unit (132) that determines whether a failure has occurred in the power module (120) using the second detection data, and maintains the power module (120) in a stopped state if it is determined that a failure has occurred in the power module (120).

[0088] The second detection data may refer to detection data collected when the power module (120) is temporarily stopped due to an abnormality being determined to have occurred in the first processing unit (131). The second detection data may include at least one of temperature data, voltage and current data, vibration and noise data, and insulation resistance data, similar to the first detection data.

[0089] The second processing unit (132) can determine whether there is an abnormality in the power module (120) in the same manner as the first processing unit (131) using the second detection data. The second processing unit (132) can determine whether there is a failure in the power module (120) using the result of the abnormality determination using the second detection data.

[0090] For example, the second processing unit (132) can count the number of times an abnormality occurs in the power module (120) using the second detection data collected over a predetermined period of time.

[0091] The second processing unit (132) can determine that a failure has occurred in the power module (120) if the number of abnormal occurrences exceeds the preset number of occurrences.

[0092] The second processing unit (132) can maintain the stopped state of the power module (120) when a failure occurs in the power module (120).

[0093] The second processing unit (132) can release the pause state of the power module (120) if the number of abnormal occurrences does not exceed the preset number of occurrences.

[0094] That is, the second processing unit (132) repeatedly determines whether there is an abnormality in the power module (120) while the operation is temporarily stopped, and if it is determined as a result of the repeated determination that an abnormality has occurred, it can ultimately determine that a failure has occurred in the power module (120).

[0095] Alternatively, the second processing unit (132) may determine the abnormal type of the power module (120), and if the number of occurrences of the same abnormal type exceeds a preset number, it may determine that a failure has occurred in the power module (120).

[0096] The second processing unit (132) can maintain the stopped state of the power module (120) when a failure occurs in the power module (120).

[0097] The second processing unit (132) can release the pause state of the power module (120) if the number of occurrences of the same abnormality type does not exceed a preset number of occurrences.

[0098] That is, the second processing unit (132) repeatedly determines whether there is an abnormality and the type of abnormality while the operation of the power module (120) is temporarily stopped, and if it is determined as a result of the repeated determination that the same type of abnormality continues to occur, it can be determined that a failure has occurred in the power module (120).

[0099] Figure 4 is an operation flowchart of an electric vehicle charging device according to an embodiment.

[0100] Referring to FIG. 4, first, the communication unit can receive first detection data from a sensor placed in the charger power module (S401).

[0101] Next, the first processing unit can use the first detection data to determine whether there is an abnormality in the power module and the type of abnormality (S402).

[0102] Next, if the first processing unit determines that an abnormality has occurred in the power module, it can temporarily suspend the operation of the power module (S403).

[0103] Next, the communication unit can receive second detection data from a sensor placed in the charger power module (S404).

[0104] Next, the second processing unit can use the second detection data to determine whether there is an abnormality in the power module (S405).

[0105] Next, the second processing unit can count the number of times an abnormality occurs in the power module using the second detection data collected over a predetermined period of time (S406).

[0106] Next, the second processing unit can determine that a failure has occurred in the power module if the number of abnormal occurrences exceeds the preset number of times (S407~408).

[0107] Next, the second processing unit can maintain the power module in a stopped state when a failure occurs in the power module (S409).

[0108] Alternatively, the second processing unit may release the power module from the pause state if the number of abnormal occurrences does not exceed the preset number of occurrences (S410).

[0109] Figure 5 is an operation flowchart of an electric vehicle charging device according to an embodiment.

[0110] Referring to FIG. 5, first, the communication unit can receive first detection data of a sensor placed in the charger power module (S501).

[0111] Next, the first processing unit can use the first detection data to determine whether there is an abnormality in the power module and the type of abnormality (S502).

[0112] Next, if the first processing unit determines that an abnormality has occurred in the power module, it can temporarily suspend the operation of the power module (S503).

[0113] Next, the communication unit can receive second detection data from a sensor placed in the charger power module (S504).

[0114] Next, the second processing unit can use the second detection data to determine whether there is an abnormality in the power module and the type of abnormality (S505).

[0115] Next, the second processing unit can count the number of times an abnormality occurs in the power module by type of abnormality using the second detection data collected over a predetermined period of time (S506).

[0116] Next, the second processing unit can determine that a failure has occurred in the power module if the number of occurrences of an abnormality of the same abnormality type exceeds a preset number of times (S507~508).

[0117] Next, the second processing unit can maintain the power module in a stopped state when a failure occurs in the power module (S509).

[0118] Alternatively, the second processing unit may release the power module from the pause state if the number of occurrences of anomalies of the same abnormal type does not exceed a preset number of occurrences (S510).

[0119] The term '~ part' used in this embodiment means a software or hardware component such as an FPGA (field-programmable gate array) or an ASIC, and the '~ part' performs certain roles. However, the '~ part' is not limited to software or hardware. The '~ part' may be configured to be on an addressable storage medium and may be configured to play one or more processors. Thus, as an example, the '~ part' includes components such as software components, object-oriented software components, class components, and task components, processes, functions, attributes, procedures, subroutines, segments of program code, drivers, firmware, microcode, circuits, data, databases, data structures, tables, arrays, and variables. The functionality provided within the components and '~ parts' may be combined into a smaller number of components and '~ parts' or further separated into additional components and '~ parts'. Additionally, components and '~parts' may be implemented to regenerate one or more CPUs within a device or secure multimedia card.

[0120] Although the present invention has been described above with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various modifications and changes may be made to the present invention without departing from the spirit and scope of the present invention as set forth in the claims below.

Claims

1. A communication unit that receives detection data from a sensor placed in a charger power module; A first processing unit that determines whether the power module is abnormal using the first detection data and temporarily suspends the operation of the power module if it is determined that an abnormality has occurred in the power module; and An electric vehicle charging device including a second processing unit that determines whether a failure has occurred in the power module using second detection data and maintains the power module in a stopped state if it is determined that a failure has occurred in the power module.

2. In paragraph 1, The above sensing data includes temperature data, voltage and current data, vibration and noise data, and insulation resistance data of an electric vehicle charging device.

3. In paragraph 1, An electric vehicle charging device in which the second processing unit counts the number of times an abnormality occurs in the power module using the second detection data collected over a predetermined period of time.

4. In paragraph 3, An electric vehicle charging device in which the second processing unit determines that a failure has occurred in the power module if the number of occurrences of the above abnormality exceeds a preset number of times.

5. In paragraph 3, The above second processing unit is an electric vehicle charging device that releases the pause state of the power module when the number of occurrences of the above abnormality does not exceed a preset number of times.

6. In paragraph 1, An electric vehicle charging device wherein the above communication unit transmits a notification message to the charger operating system when it is determined that a failure has occurred in the above power module.

7. In paragraph 1, The above second processing unit is an electric vehicle charging device that determines the abnormal type of the power module.

8. In paragraph 7, An electric vehicle charging device in which the second processing unit determines that a failure has occurred in the power module when the number of occurrences of the same abnormal type exceeds a preset number of times.

9. In paragraph 7, An electric vehicle charging device in which the second processing unit releases the pause state of the power module when the number of occurrences of the same abnormal type does not exceed a preset number of times.

Images