Systems and methods for performing thermal management of chargers

Abstract

Embodiments herein disclose methods and systems for performing thermal management of one or more chargers in a charging and interchange station. Embodiments herein disclose systems and methods for performing thermal management of chargers in a charging and interchange station that is efficient, cost-effective, and easy to install and maintain

Description

Systems and methods for performing thermal management of chargersCROSS REFERENCE TO RELATED APPLICATIONThis application is based on and derives the benefit of Indian Provisional Application IN202441065103, the contents of which are incorporated herein by reference.TECHNICAL FIELD

[0001] Embodiments disclosed herein relate to chargers in a charging and interchange station, and more particularly to systems and methods for performing thermal management of chargers in a charging and interchange station.BACKGROUND

[0002] Electric vehicles (EVs) have emerged as a cleaner and more sustainable alternative to conventional internal combustion (IC) engine vehicles. Their adoption is driven by the growing need to reduce carbon emissions, combat climate change, and minimize dependence on fossil fuels. EVs offer the advantage of lower operating costs and reduced environmental impact. However, their widespread adoption continues to face key obstacles, for example, limited driving range, long charging times, inadequate charging infrastructure, and the relatively high cost of battery systems.

[0003] To address these challenges, battery swapping (also known as electrical energy storage device interchange) has gained attention as a practical and scalable solution. Instead of waiting for a battery to recharge, a user can quickly exchange a depleted energy storage device with a fully charged one at a designated interchange station. This method significantly reduces vehicle downtime and relieves concerns about range and long queues at charging points, making EV use more convenient and accessible for both personal and commercial applications.

[0004] Despite its advantages, battery swapping introduces new operational complexities. At the charging and interchange stations, depleted energy storage devices are inserted into dedicated docks where they are charged using high-power chargers. These chargers generate significant heat during operation, which must be carefully managed to ensure they remain within optimal operating limits. Effective thermal management not only improves charging efficiency, but also extends the lifespan of the chargers and supports the long-term reliability and sustainability of the interchange system.

[0005] Hence, there is a need in the art for solutions which will overcome the above mentioned drawback(s), among others.OBJECTS

[0006] The principal object of embodiments herein is to disclose methods and systems for performing thermal management of one or more chargers in a charging and interchange station.

[0007] Another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that is efficient, cost-effective, and easy to install and maintain.

[0008] Yet another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that can automatically regulate charger temperatures to prevent overheating during prolonged operations.

[0009] Still another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that improve the operational lifespan and reliability of chargers used in electrical energy storage device interchange stations.

[0010] Another object of embodiments herein is to provide systems and methods for performing thermal management of chargers in a charging and interchange station that provides real-time monitoring and control of thermal parameters associated with at least one charger in a single or multi-rack setup.

[0011] Yet another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that ensures safe operation of high-power chargers by preventing thermal runaway or damage due to excessive heat buildup.

[0012] Another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that enables intelligent distribution of charging loads among chargers based on their thermal state and operating efficiency.

[0013] Still another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station thatintegrates thermal management solutions without significantly increasing the physical footprint or complexity of the charging station.

[0014] Another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that optimizes energy usage in the thermal management system to ensure minimal power wastage during heat dissipation or cooling.

[0015] Yet another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that supports scalability and modular deployment of thermal management systems across various types of charging and interchange stations.

[0016] Another object of embodiments herein is to disclose systems and methods for performing thermal management of chargers in a charging and interchange station that facilitates data logging and diagnostics for predictive maintenance of chargers based on their thermal performance trends.

[0017] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating at least one embodiment and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.SUMMARY

[0018] Embodiments herein disclose systems for thermal management of chargers in a charging and interchange station, wherein the system comprises a plurality of rectifiers for charging one or more electrical energy storage devices placed in various docks. An inlet conduit is connected to these rectifiers for supplying coolant, while an outlet conduit carries the heated coolant away from the rectifiers. The rectifiers are preferably liquid-cooled and arranged in stacks, and the system may also include a bypass conduit with a degassing and collection tank to handle coolant flow based on predefined temperature ranges. A condenser is connected to the outlet conduit, and a fan is positioned on the same conduit to cool the hot coolant exiting from the rectifiers. One or more pumps are provided to pressurize and circulate coolant through the rectifiers for effective heat absorption. The system also includes a RackSupervising Unit (RSU), which monitors and controls the overall thermal management process for the rectifiers. Additional features such as temperature sensors at rectifier inlets and outlets, solenoid valves for individual stack control, and logic for load-sharing or fault-based operation further enhance the system’s adaptability and safety.

[0019] Embodiments herein disclose a method for thermal management of chargers in a charging and interchange station, wherein the method includes authenticating, by the RSU, an electrical energy storage device inserted into a dock. The RSU then initiates the charging process through one or more rectifiers, the RSU continuously monitors the inlet and outlet temperatures of these rectifiers using sensors and compares the temperature values. If the difference in temperature remains below a predetermined threshold, the charging process is allowed to continue. However, if the temperature difference equals or exceeds the threshold, the RSU terminates the charging operation and notifies an operator of a potential overheating error. This method ensures controlled and safe operation by using real-time thermal data to regulate charger functionality.

[0020] Embodiments herein disclose a method for controlling coolant flow in a charging and interchange station, wherein the method involves the use of solenoid valves positioned at the inlet of each rectifier stack. These valves remain open when all rectifiers in the stack are functioning normally, allowing unrestricted coolant flow. If any rectifier within a stack fails, the solenoid valve closes to block coolant flow and terminate the charging process for that specific stack. Upon valve closure, the corresponding pump is instructed to reduce its coolant flow rate to prevent pressure build-up or waste. This method ensures precise thermal control and localized fault isolation for improved station performance.

[0021] Embodiments herein disclose a method for managing coolant flow specifically for large-capacity electrical energy storage devices, wherein the method involves configuring rectifier stacks into a loop arrangement that acts as a single large rectifier. The solenoid valve at the inlet of this loop remains open when all rectifiers are operational. In the event of partial rectifier failure within the loop, the valve stays open and allows coolant flow at a de-rated charging rate while maintaining the flow rate. However, if all rectifiers in the loop fail, the solenoid valve closes, thereby stopping coolant flow and terminating charging for that loop. The system also notifies the corresponding pump to reduce the flow rate when the valve closes, ensuring controlled coolant dynamics under all operating conditions.BRIEF DESCRIPTION OF FIGURES

[0022] Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the following illustrative drawings. Embodiments herein are illustrated by way of examples in the accompanying drawings, in which:

[0023] FIG. 1 illustrates a system for performing thermal management of chargers in a charging and interchange station, according to embodiments as disclosed herein; and

[0024] FIG. 2 illustrates an example system for performing thermal management of chargers in a charging and interchange station, according to embodiments as disclosed herein;

[0025] FIG. 3 is a flow chart depicting the process of performing thermal management of chargers in a charging and interchange station, according to embodiments as disclosed herein;

[0026] FIG. 4 is a flow chart depicting the process of controlling the radiator fan for performing thermal management in a charging and interchange station, according to embodiments as disclosed herein;

[0027] FIG. 5 illustrates an example scenario, wherein thermal management is performed in a charging and interchange station during a rectifier failure, according to embodiments as disclosed herein; and

[0028] FIG. 6 illustrates an example scenario, wherein thermal management is performed in a charging and interchange station during a rectifier failure, according to embodiments as disclosed herein.DETAILED DESCRIPTION

[0029] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as not to unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0030] For the purposes of interpreting this specification, the definitions (as defined herein) will apply, and whenever appropriate, the terms used in the singular will also include the plural and vice versa. It is to be understood that the terminology used herein is for the purposes of describing particular embodiments only and is not intended to be limiting. The terms “comprising”, “having” and “including” are to be construed as open-ended terms unless otherwise noted.

[0031] The words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” are merely used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein using the words / phrases "exemplary", “example”, “illustration”, “in an instance”, “and the like”, “and so on”, “etc.”, “etcetera”, “e.g.,”, “i.e.,” is not necessarily to be construed as preferred or advantageous over other embodiments.

[0032] Embodiments herein may be described and illustrated in terms of blocks which carry out a described function or functions. These blocks, which may be referred to herein as managers, units, modules, hardware components or the like, are physically implemented by analogue and / or digital circuits such as logic gates, integrated circuits, microprocessors, microcontrollers, memory circuits, passive electronic components, active electronic components, optical components, hardwired circuits and the like, and may optionally be driven by a firmware. The circuits may, for example, be embodied in one or more semiconductor chips, or on substrate supports such as printed circuit boards and the like. The circuits constituting a block may be implemented by dedicated hardware, or by a processor (e.g., one or more programmed microprocessors and associated circuitry), or by a combination of dedicated hardware to perform some functions of the block and a processor to perform otherfunctions of the block. Each block of the embodiments may be physically separated into two or more interacting and discrete blocks without departing from the scope of the disclosure. Likewise, the blocks of the embodiments may be physically combined into more complex blocks without departing from the scope of the disclosure.

[0033] It should be noted that elements in the drawings are illustrated for the purposes of this description and ease of understanding and may not have necessarily been drawn to scale. For example, the flowcharts / sequence diagrams illustrate the method in terms of the steps required for understanding aspects of the embodiments as disclosed herein. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Furthermore, in terms of the system, one or more components / modules which comprise the system may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the present embodiments so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0034] The accompanying drawings are used to help easily understand various technical features and it should be understood that the embodiments presented herein are not limited by the accompanying drawings. As such, the present disclosure should be construed to extend to any modifications, equivalents, and substitutes in addition to those which are particularly set out in the accompanying drawings and the corresponding description. Usage of words such as first, second, third etc., to describe components / elements / steps is for the purposes of this description and should not be construed as sequential ordering / placement / occurrence unless specified otherwise.

[0035] The embodiments herein achieve methods and systems for performing thermal management of one or more chargers in a charging and interchange station. Referring now to the drawings, and more particularly to FIGS. 1 through 6, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.

[0036] The following terms and reference numerals have been referred to herein:100 - System for Thermal Management of Chargers (CTMS)105 - Condenser110 - Fan115 - Inlet conduit120 - Pump125 - Outlet conduit130 - Bypass conduit135 - Degassing and collection unit140 - Solenoid valveT - Temperature sensorR - RectifierRF - Faulty Rectifier

[0037] FIGs. 1-6 depicts systems and methods for performing thermal management of chargers in a charging and interchange station. The system for thermal management of chargers is monitored and operated by a Rack Supervising Unit (RSU), wherein the RSU is provided in the charging and interchange station. The charging and interchange station is provided with one or more docks, wherein each dock is configured to accommodate at least one cassette, and each cassette can include at least one electrical energy storage device.

[0038] FIG. 1 illustrates a system 100 for thermal management of chargers in a charging and interchange station. The system 100 comprises a plurality of rectifiers R for charging electrical energy storage devices, a condenser 105, a fan 110, an inlet conduit 115, one or more pumps 120, an outlet conduit 125, a bypass conduit 130, and a degassing and collection tank 135. These components work together to efficiently manage the thermal conditions of the chargers during the charging process.

[0039] The system 100 is equipped with chargers having a plurality of rectifiers R for charging a plurality of electrical energy storage devices placed in a plurality of docks of the charging and interchange station. Each dock can be dynamically assigned a specific number of rectifiers R based on parameters such as, but not limited to, the capacity of the electrical energy storage device, rectifier capacity, charge rate, thermal management requirements, conditioningrequirements, and so on. For instance, a 45KWH capacity electrical energy storage device can be assigned two rectifiers of 30KWH capacity each to be charged at 1.6C, while a 90KWH capacity electrical energy storage device can be assigned five rectifiers of 30KWH capacity each to be charged at 1.6C.

[0040] In an embodiment herein, the rectifier R can be a liquid-cooled rectifier. The rectifiers R are provided with an inlet and an outlet fluid connector connecting the inlet conduit 115 and the outlet conduit 125. The conduits facilitate the circulation of coolant through the rectifiers for heat absorption. The outlet conduit 125 is further connected to a condenser 105. Additionally, the outlet conduit 125 can have a fan 110 for cooling the hot coolant emerging out of the rectifier R. A bypass conduit 130 can be provided on the outlet conduit 125 to bypass the condenser 105 if the coolant is within a pre-defined temperature range (for instance, 10 - 27 degree Celsius) and does not need cooling. This feature helps in maintaining energy efficiency by avoiding unnecessary cooling when the coolant temperature is already within an acceptable range. Further, the bypass conduit 130 can be provided with a degassing and collection tank 135. The degassing and collection tank 135 serves multiple purposes, including degassing the coolant, collecting excess coolant, and replenishing the coolant (as needed). The degassing process helps remove any air bubbles or gases that may have accumulated in the coolant during circulation, ensuring optimal heat transfer efficiency.

[0041] In an embodiment herein, one or more pumps 120 may be employed at each dock to pressurize and circulate the coolant within the rectifiers R for heat absorption. The pump(s) 120 can be individually controlled to adjust the flow of coolant within the rectifiers based on the cooling requirements of each rectifier. This allows for precise thermal management and optimal charging conditions for the electrical energy storage devices.

[0042] The system 100 can be configured to accommodate various arrangements of rectifier stacks for efficient thermal management. For example, multiple rectifiers can be connected in series within each rectifier stack to facilitate efficient coolant circulation. These series-connected rectifier stacks can then be further connected in parallel to optimize the overall charging and cooling process.

[0043] Temperature monitoring across each rectifier is achieved through temperature sensors placed at both the inlet and outlet points of the rectifiers. These sensors provide realtime temperature data to the RSU, which monitors and controls the thermal managementsystem. The RSU authenticates the electrical energy storage device, initiates the charging process, and continuously monitors the inlet and outlet temperatures of the rectifiers.

[0044] If the temperature difference between the inlet and outlet of a rectifier is less than a predetermined temperature threshold (for example, 4 Degree Celsius, 5 degrees Celsius, 7 Degree Celsius, 8 Degree Celsius, and so on), the RSU continues the charging process normally. However, if the temperature difference is equal to or greater than the predetermined temperature threshold, the RSU notifies the operator of an overheating error in the rectifier and terminates the charging process for that particular rectifier.

[0045] In addition to temperature monitoring, the system 100 incorporates a radiator fan control process. The RSU first detects and verifies the electrical energy storage device inserted into the dock for charging. Once verified, the RSU initiates the charging process, and the RSU analyses the coolant temperature at the inlet and outlet of the rectifier using the temperature sensors. Based on the temperature difference, the RSU controls the operation of the radiator fan 110 to maintain optimal cooling conditions. The RSU can be implemented using various hardware configurations, including microcontrollers, field-programmable gate arrays (FPGAs), or application-specific integrated circuits (ASICs), depending on the specific requirements of the charging station.

[0046] The system 100 also includes solenoid valves at the inlet of each rectifier stack to control the flow of coolant. The solenoid valves can be opened or closed based on the working condition of the rectifiers in the stack. For instance, if all rectifiers in a stack are functioning normally, the solenoid valve remains open. If a rectifier fails, the RSU can adjust the coolant flow and charging rate accordingly, or in some cases, terminate the charging process for that particular stack.

[0047] In cases where a large capacity electrical energy storage device is being charged (such as a 90KWH unit), the rectifier stack can be looped to behave as a single rectifier. This configuration allows for efficient charging of high-capacity devices while maintaining proper thermal management.

[0048] The number of pumps 120 and solenoid valves can be varied based on the number of docks present in the specific rack of the charging and interchange station. This flexibility allows for scalability and customization of the thermal management system to accommodate different charging station configurations and capacities.

[0049] FIG. 2 illustrates example arrangements of rectifier stacks for thermal management in a charging and interchange station. FIG. 2 depicts two example configurations of rectifier stacks, each designed to efficiently manage the thermal aspects of the charging process for electrical energy storage devices. These arrangements demonstrate the flexibility and scalability of the system to accommodate various charging requirements and electrical energy storage device capacities.

[0050] In the example depicted in FIG. 2-(A), two rectifier stacks are shown connected in parallel, with each stack comprising three rectifiers R connected in series. This configuration is suitable for charging electrical energy storage devices with moderate capacity requirements. The rectifiers R are liquid-cooled units, wherein each rectifier can be equipped with an inlet and outlet fluid connector for the circulation of coolant. The inlet conduit 115 supplies coolant to the rectifiers, while the outlet conduit 125 carries the heated coolant away from the rectifiers.

[0051] The series connection within each stack of rectifiers allows for efficient coolant circulation through the rectifiers. As the coolant flows through the series-connected rectifiers, the rectifiers absorb heat generated during the charging process. This arrangement ensures that the coolant temperature gradually increases as it passes through each rectifier, maximizing the heat absorption capacity of the coolant before it exits the stack.

[0052] The parallel connection between the two rectifier stacks provides redundancy and allows for increased charging capacity. If one rectifier stack experiences a malfunction or requires maintenance, the other rectifier stack can continue to operate, ensuring uninterrupted charging services. Additionally, this parallel arrangement allows for load balancing between the rectifier stacks, distributing the charging load evenly and potentially extending the lifespan of the rectifiers.

[0053] FIG. 2-(B) presents an example alternative configuration with three rectifier stacks connected in parallel, wherein each rectifier stack contains two rectifiers R connected in series. This arrangement is suitable for charging electrical energy storage devices with higher capacity requirements or for handling multiple charging sessions simultaneously. The increased number of parallel stacks provides greater overall charging capacity and improved thermal management capabilities.

[0054] In this configuration, the coolant flow is divided among the three parallel rectifier stacks, allowing for more efficient heat dissipation. The series connection within each rectifier stack maintains the gradual temperature increase of the coolant as it passes throughthe rectifiers. The parallel arrangement of the rectifier stacks ensures that the heat load is distributed more evenly across the system, potentially reducing the overall temperature rise in any single rectifier stack.

[0055] The rectifiers R in both configurations (2-(A) and 2-(B)) are designed to be modular and interchangeable. This modularity allows for easy maintenance, replacement, or upgrades of individual rectifiers without disrupting the entire system. The rectifiers can be individually controlled to vary the flow of coolant based on the amount of cooling required, optimizing the thermal management process.

[0056] Each rectifier R is equipped with temperature sensors T at both the inlet and outlet points. These sensors continuously monitor the coolant temperature, providing real-time data to the Rack Supervisory Unit (RSU) for efficient thermal management. The RSU uses this temperature data to control the cooling system (which includes the fans, pumps, and solenoid valves), including the operation of fans, pumps, and solenoid valves, ensuring optimal thermal conditions for the charging process.

[0057] The inlet conduit 115 and outlet conduit 125 are designed to handle the required coolant flow rates for effective heat dissipation. The conduits are made of materials resistant to the coolant used in the system, ensuring long-term reliability and preventing coolant leakage. The conduits are also insulated to minimize heat transfer with the surrounding environment, maintaining the efficiency of the cooling system.

[0058] In both configurations, the rectifier stacks can be assigned to different docks in the charging and interchange station based on the capacity of the electrical energy storage devices being charged. For example, a 45KWH capacity electrical energy storage device might be assigned to a single stack in the FIG. 2-(A) configuration, while a 90KWH capacity device could utilize multiple stacks from the FIG. 2-(B) configuration to achieve the desired charging rate.

[0059] The flexibility of these rectifier stack arrangements allows the charging and interchange station to adapt to various charging scenarios and electrical energy storage device capacities. By optimizing the thermal management of the rectifiers, the system ensures efficient and reliable charging while prolonging the lifespan of both the charging equipment and the electrical energy storage devices.

[0060] FIG. 3 illustrates a method of temperature monitoring across each rectifier based on the coolant temperature in the thermal management system for chargers in a charging andinterchange station 100. Each rectifier is equipped with temperature sensors T at both the inlet and outlet points. The RSU monitors and controls the system for performing thermal management of chargers.

[0061] As the depleted energy storage device (EESD) (i.e., cassette) is inserted for charging, the electrical energy storage device is authenticated by the RSU by verifying the live data from the electrical energy storage unit and charger over a network (such as, but not limited to, a Control Area Network (CAN), a Local Interconnect Network (LIN), and so on). Once the electrical energy storage device is authenticated, the RSU initiates the charging process through a plurality of rectifiers R. The RSU confirms the charging status of the electrical energy storage device and proceeds to check the inlet and outlet temperature of the rectifier through the temperature sensors T over a Programmable Logic Controller (PLC). The RSU can use the temperature difference for assessing the thermal performance of the rectifiers and ensuring their safe operation. The RSU can make decisions based on this temperature difference, implementing a threshold-based control strategy. The RSU compares the inlet and outlet temperatures of the selected rectifiers. The RSU proceeds with charging if the temperature difference (At) between the inlet and outlet temperature is less than the predetermined temperature threshold. This indicates that the rectifier is operating within acceptable thermal limits, and the coolant is effectively dissipating the heat generated during the charging process. If the temperature difference is greater than or equal to predetermined temperature threshold, the RSU takes immediate action to prevent potential damage to the rectifier and ensure safety. The RSU immediately notifies the operator of an overheating error in the rectifier R and terminates the charging process. The notification can be at least one of displayed on a user interface in the station, sent as an alert to a mobile device, or integrated into the station's overall monitoring system.

[0062] The method illustrated in FIG. 3 can be further enhanced by implementing additional features such as predictive maintenance algorithms, which analyse temperature trends over time to anticipate potential rectifier failures before they occur. Moreover, the system can be designed to automatically adjust coolant flow rates or activate auxiliary cooling systems based on the temperature readings, further optimizing the thermal management process.

[0063] In alternative embodiments, the temperature monitoring method can be integrated with other parameters such as charging current, voltage, and battery state of charge to provide a comprehensive charging and thermal management solution. This holistic approachcan lead to improved efficiency, extended equipment lifespan, and enhanced safety in charging and interchange stations for electrical energy storage devices.

[0064] FIG. 4 illustrates a flowchart depicting the process of controlling the radiator fan 110 in the thermal management system for chargers in a charging and interchange station 100. The RSU first detects and verifies the electrical energy storage device (EESD) (i.e., cassette) being inserted into the dock for charging. This step involves the RSU authenticating the EESD by verifying live data from both the EESD and the charger over a network, such as, but not limited to, a Control Area Network (CAN) or a Local Interconnect Network (LIN). The RSU ensures that the EESD is compatible with the charging system and is ready to receive a charge.

[0065] Once the electrical energy storage is verified, the RSU initiates the charging process. As the charging process begins, the RSU continuously monitors the live data from the rectifiers R and the EESD. This step is crucial to ensure that at least one EESD is actively charging and sending live data. If no EESD is charging or sending data, the process returns to the detection and verification stage. The RSU then proceeds to analyse the temperature of the coolant at the inlet and outlet of the rectifier through the temperature sensors T placed at the inlet and outlet of the rectifier. The RSU compares the inlet and outlet temperatures of the coolant. If the temperature difference (At) between the inlet and outlet temperatures is less than the predetermined temperature threshold, the RSU activates the radiator fan 110. The radiator fan 110 is designed to cool the hot coolant emerging from the rectifiers R, ensuring that the coolant temperature remains within an optimal range for efficient charging and longevity of the system components. If the temperature difference (At) is greater than or equal to the predetermined temperature threshold, the RSU interprets this as an indication of potential overheating in the rectifier R. In such cases, the RSU takes immediate action by sending an error message to the operator and stopping the charging process for the affected rectifier or rectifier stack. This safety measure prevents damage to the rectifiers and ensures the overall integrity of the charging system.

[0066] The radiator fan 110 can be controlled to operate at variable speeds, depending on the cooling requirements. In some embodiments, the fan speed can be adjusted based on the magnitude of the temperature difference, allowing for more efficient energy usage while maintaining optimal cooling performance.

[0067] It's important to note that the predetermined temperature threshold can be adjusted based on specific system requirements, environmental conditions, or regulatory standards. The system can be programmed with different temperature thresholds for various operating conditions or electrical energy storage device types.

[0068] In alternative embodiments, the system may incorporate additional sensors to monitor other parameters such as, but not limited to, coolant pressure, flow rate, or electrical characteristics of the rectifiers. These additional data points can be integrated into the control logic to provide more comprehensive thermal management and system diagnostics.

[0069] The flow chart in FIG. 4 represents a continuous loop, with the RSU constantly monitoring and adjusting the system to maintain optimal charging conditions. This real-time responsiveness ensures efficient operation, prolongs the life of system components, and enhances the overall reliability of the charging and interchange station.

[0070] In an embodiment herein, a solenoid valve 140 is provided at the inlet of each rectifier stack. The solenoid valve 140 is configured to allow or restrict the flow of coolant into the rectifier stack. FIGs. 5 and 6 depict the working of the solenoid valve 140 under ideal working conditions and during rectifier failure conditions.

[0071] FIG. 5 illustrates the solenoid valve 140 provided at the inlet of each rectifier stack in a system for thermal management of chargers in a charging and interchange station. The figure depicts three scenarios: (A) normal operation, (B) failure of one rectifier in a stack, and (C) failure of one rectifier in a loop configuration. The system comprises an inlet conduit 115, a pump 120, an outlet conduit 125, a solenoid valve 140, a plurality of rectifiers R, and at least one faulty rectifier RF.

[0072] In FIG. 5-(A), the solenoid valve 140 is shown in open condition as all the rectifiers are in working condition, allowing the flow of coolant into the rectifier stack. This represents the ideal working condition where all rectifiers R are functioning properly. The coolant enters through the inlet conduit 115, passes through the open solenoid valve 140, and circulates through the rectifiers R before exiting via the outlet conduit 125. The pump 120 maintains the circulation of the coolant at a normal flow rate.

[0073] FIG. 5-(B) illustrates a scenario where one of the rectifiers in the stack has failed, represented by the faulty rectifier RF. If one of the rectifiers RF of the rectifier stack fails, the solenoid valve 140 closes, thereby restricting the flow of coolant into the rectifier stack and the charging process is terminated for that particular stack. The RSU can furthernotify the corresponding pump 120 to pump the coolant at a lower flow rate than usual, adapting to the reduced cooling requirements of the system.

[0074] In FIG. 5-(C), an alternative failure scenario is presented where one rectifier in the stack in a loop configuration has failed, but the solenoid valve 140 remains open. If one of the rectifiers RF of the rectifier stack fails, the solenoid valve 140 is open, thereby allowing the flow of coolant into the rectifier stack. In this condition, the charging rate is reduced to accommodate the decreased efficiency of the stack, while the coolant flow rate is maintained at its normal level. This approach allows for continued operation of the charging system, albeit at a reduced capacity, rather than completely shutting down the affected stack.

[0075] FIG. 6 illustrates the solenoid valve 140 in rectifier loop configurations for a thermal management system in a charging and interchange station. FIG. 6 depicts three rectifier loops, each containing multiple rectifiers R connected in series. The solenoid valves 140 are positioned at the inlet of each rectifier loop to control the flow of coolant. FIG. 6 shows different scenarios of rectifier operation and failure, demonstrating how the system responds to maintain efficient cooling and charging processes.

[0076] In FIG. 6-(A), the solenoid valve 140 is in open condition as all the rectifiers are in working condition, allowing coolant to flow through each rectifier loop. In the condition depicted in FIG. 6-(A), the rectifier stack is looped to behave as a single rectifier. This configuration enables optimal cooling and charging performance for electrical energy storage devices of large capacity, where multiple rectifiers are required to handle the charging load.

[0077] FIG. 6-(B) illustrates a scenario where one rectifier in loop 2 has failed, as indicated by the faulty rectifier RF. If one of the rectifiers RF in the rectifier loop fails, the solenoid valve 140 remains open, thereby allowing the flow of coolant into the rectifier stack at a de-rated charging condition (i.e., the EESD is being charged at a lower power) to compensate for the failed rectifier. This approach maintains the coolant flow rate while reducing the charging rate, ensuring continued operation of the remaining functional rectifiers in the loop.

[0078] FIG. 6-(C) demonstrates a situation where all rectifiers in Loop 3 have failed, as shown by the multiple faulty rectifiers RF. If all the rectifiers RF in the rectifier loop fail, the solenoid valve 140 closes, thereby restricting the flow of coolant into the specific rectifier loop, wherein the charging process is terminated for the particular loop. This action prevents unnecessary coolant circulation through non-functional rectifiers and allows the system toredirect coolant to the operational loops. The corresponding pump 120 is notified to pump the coolant at a lower flow rate than usual, while conserving energy and optimizing coolant distribution to the functioning loops.

[0079] The rectifier loops shown in FIG. 6 can be configured to behave as a single rectifier unit when charging large capacity electrical energy storage devices. This configuration allows for efficient distribution of the charging load across multiple rectifiers, enhancing the overall charging capability of the system. The loop arrangement also provides redundancy, allowing the system to continue functioning even if individual rectifiers fail.

[0080] In an embodiment herein, the pump 120 is responsible for circulating the coolant through the entire network of rectifiers. In an embodiment herein, the pump 120 can be one of a centrifugal pump, a positive displacement pump, and so on. The pump 120 can be capable of maintaining a consistent flow rate under varying pressure conditions. The pump 120 may be equipped with variable speed control, wherein the pump 120 can adjust its output based on the cooling demands of the system. In some embodiments, multiple pumps could be employed in parallel or series configurations to provide redundancy or to handle different zones of the charging station independently.

[0081] In an embodiment herein, the inlet conduit 115 and the outlet conduit 125 may be constructed from materials (such as, but not limited to, stainless steel, copper, high-grade polymers, and so on) depending on the specific requirements of the system. In an embodiment herein, the inlet conduit 115 could incorporate one or more insulation layers. In an embodiment herein, the inlet conduit 115 can be equipped with one or more temperature sensors to monitor coolant temperature at various points along the length of the inlet conduit 115. In an embodiment herein, the outlet conduit 125 could incorporate one or more insulation layers. In an embodiment herein, the outlet conduit 125 can be equipped with one or more temperature sensors to monitor coolant temperature at various points along the length of the outlet conduit 125.

[0082] The solenoid valve 140 controls the flow of coolant to each rectifier stack. In an embodiment herein, the solenoid valve 140 is an electrically operated valve that can rapidly open or close in response to signals from the RSU. The solenoid valve 140 may comprise of a coil, a plunger, and a valve body (not shown). When energized, the coil creates a magnetic field that moves the plunger, which in turn opens or closes the valve. In an embodiment herein, the solenoid valve 140 could be a proportional type, allowing for variable flow control rather thanjust binary open / close operations. This would enable more nuanced thermal management strategies.

[0083] The rectifiers R are responsible for converting AC power to DC for charging the electrical energy storage devices. The rectifiers R generate significant heat during operation, necessitating efficient cooling. In an embodiment herein, each rectifier R may be equipped with one or more internal temperature sensors. In an embodiment herein, each rectifier R may have individual coolant flow paths to allow for targeted cooling. In alternative embodiments, the rectifiers could employ different cooling technologies (such as, but not limited to, heat pipes, thermoelectric cooling, and so on) in conjunction with liquid cooling for enhanced thermal management.

[0084] The faulty rectifiers RF represent units that have malfunctioned or are operating outside of acceptable parameters. The system's ability to detect and respond to faulty rectifiers is crucial for maintaining overall efficiency and preventing cascading failures. In advanced implementations, predictive maintenance algorithms could be employed to anticipate potential rectifier failures before they occur, allowing for proactive maintenance and minimizing downtime.

[0085] The embodiments disclosed herein can be implemented through at least one software program running on at least one hardware device and performing network management functions to control the network elements. The elements include blocks which can be at least one of a hardware devices, or a combination of hardware devices and software modules.

[0086] The embodiments disclosed herein describe methods and systems for performing thermal management of one or more chargers in a charging and interchange station. Therefore, it is understood that the scope of the protection is extended to such a program and in addition to a computer readable means having a message therein, such computer readable storage means contain program code means for implementation of one or more steps of the method, when the program runs on a server or mobile device or any suitable programmable device. The method is implemented in at least one embodiment through or together with a software program written in e.g., Very high speed integrated circuit Hardware Description Language (VHDL) another programming language, or implemented by one or more VHDL or several software modules being executed on at least one hardware device. The hardware device can be any kind of portable device that can be programmed. The device may also include meanswhich could be e.g., hardware means e.g., an ASIC, or a combination of hardware and software means, e.g. an ASIC and an FPGA, or at least one microprocessor and at least one memory with software modules located therein. The method embodiments described herein could be implemented partly in hardware and partly in software. Alternatively, the invention may be implemented on different hardware devices, e.g., using a plurality of CPUs.

[0087] The embodiments described herein have several technical advantages including, but not limited to, thermal management of chargers in the charging and interchange station,- that enable active and real-time thermal regulation of chargers during operation, ensuring they function within optimal temperature ranges;- that facilitate adaptive control of cooling resources based on operational demand, improving system responsiveness and reducing energy waste;- that support localized thermal decision-making, allowing partial operation of the system even when certain charging elements are degraded or non-functional;- that provide centralized monitoring and automated control to enhance system reliability, safety, and operational continuity;- that allow functional scalability across different station sizes and charger capacities, accommodating future expansion or reconfiguration;- that enable intelligent fault detection and handling to prevent thermal damage and support uninterrupted service;- that improve the functional lifespan and efficiency of the system by preventing overheating- related failures;- that reduce the need for manual oversight by enabling automated diagnostics and conditionbased maintenance;- that enhance safety through timely intervention based on predefined thermal thresholds and operational criteria; and- that maintain thermal stability across multiple chargers without compromising compactness, modularity, or serviceability of the overall system.

[0088] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments withoutdeparting from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments and examples, those skilled in the art will recognize that the embodiments and examples disclosed herein can be practiced with modification within the scope of the embodiments as described herein.

Claims

STATEMENT OF CLAIMSWe claim:

1. A charging and interchange station, comprising: a plurality of rectifiers (R) for charging a plurality of electrical energy storage devices placed in at least one dock of the charging and interchange station; an inlet conduit (115) connected to the plurality of rectifiers (R); an outlet conduit (125) connected to the plurality of rectifiers (R); a condenser (105) connected to the outlet conduit (125); a fan (110) positioned on the outlet conduit (125) for cooling hot coolant emerging from the plurality of rectifiers (R); one or more pumps (120) configured to pressurize and circulate coolant within the plurality of rectifiers (R) for heat absorption; and a Rack Supervising Unit (RSU) configured to monitor and control the plurality of rectifiers (R), the fan (110), and the one or more pumps (120).

2. The charging and interchange station as claimed in claim 1, wherein the plurality of rectifiers (R) are liquid-cooled rectifiers.

3. The charging and interchange station as claimed in claim 1, wherein each dock is assigned at least one rectifier (R) based on capacity of the electrical energy storage device present in the dock, rectifier capacity, charge rate, thermal management requirements, and conditioning requirements.

4. The charging and interchange station as claimed in claim 1, wherein the system includes a bypass conduit (130) provided on the outlet conduit (125) to bypass the condenser (105) if the coolant is within a pre-defined temperature range, wherein the bypass conduit (130) includes a degassing and collection tank (135) for degassing, collection, and replenishment of the coolant.

5. The charging and interchange station as claimed in claim 1, wherein the RSU is configured to control the one or more pumps (120) individually to vary the flow of coolant within the plurality of rectifiers (R) based on the amount of cooling required.

6. The charging and interchange station as claimed in claim 1, wherein the plurality of rectifiers (R) are arranged in a plurality of rectifier stacks connected in parallel, wherein each stack comprises two or more rectifiers (R) connected in series.

7. The charging and interchange station as claimed in claim 6, wherein the rectifier stack is looped to behave as a single rectifier, on an electrical energy storage device of large capacity being present in the dock.

8. The charging and interchange station as claimed in claim 1, wherein each rectifier (R) is equipped with at least one temperature sensor (T) at an inlet of the rectifier (R), and an outlet point of the rectifier (R).

9. The charging and interchange station as claimed in claim 8, wherein the Rack Supervising Unit (RSU) is configured to: authenticate the electrical energy storage device present in the dock; initiate the charging of the electrical energy storage device through the plurality of rectifiers (R), on successfully authenticating the electrical energy storage device; confirm that the electrical energy storage device is being charged, on initiating the charging of the electrical energy storage device; monitor temperature of the inlet and outlet temperatures of the rectifier through the at least one temperature sensor (T); determine a temperature difference between the inlet and outlet temperatures of the rectifiers (R); continue charging of the electrical energy storage device using the rectifiers (R), and turn on the fan (110), if the temperature difference between the inlet and outlet temperatures is less than a predetermined temperature threshold; and notifying an operator of an overheating error in the rectifier (R) and terminating the charging process, if the temperature difference between the inlet and outlet temperatures is greater than or equal to the predetermined temperature threshold.

10. The charging and interchange station as claimed in claim 1, wherein the charging and interchange station includes a solenoid valve (140) provided at the inlet of each rectifier stack, wherein the solenoid valve (140) is configured to allow or restrict the flow of coolant into the rectifier stack.

11. The charging and interchange station as claimed in claim 10, wherein the solenoid valve (140) is configured to close, thereby restricting the flow of coolant into the rectifier stack and terminating the charging process for that particular stack, if one of the rectifiers of the rectifier stack fails, wherein the corresponding pump (120) is notified to pump the coolant at a lower flow rate when the solenoid valve (140) closes.

12. The charging and interchange station as claimed in claim 10, wherein the solenoid valve (140) is configured to remain open, thereby allowing the flow of coolant into the rectifier stack at a reduced charging rate while maintaining the flow rate, if one of the rectifiers of the rectifier stack fails.

13. The charging and interchange station as claimed in claim 10, wherein the solenoid valve (140) is configured to remain open, thereby allowing the flow of coolant into the rectifier stack at de-rated charging condition while maintaining the flow rate, if one of the rectifiers in the rectifier loop fails.

14. The charging and interchange station as claimed in claim 10, wherein the solenoid valve (140) is configured to close, thereby restricting the flow of coolant into the specific rectifier loop and terminating the charging process for the particular loop, if all the rectifiers in the rectifier loop fail, wherein the corresponding pump (120) is notified to pump the coolant at a lower flow rate than usual when the solenoid valve (140) closes.

15. A method for thermal management of chargers in a charging and interchange station, comprising: authenticating, by a Rack Supervising Unit (RSU), an electrical energy storage device inserted into a dock; initiating, by the Rack Supervising Unit (RSU), a charging of the electrical energy storage device through a plurality of rectifiers (R), on successfully authenticating the electrical energy storage device; monitoring, by the Rack Supervising Unit (RSU), inlet and outlet temperatures of the plurality of rectifiers (R) using temperature sensors (T) placed at inlet and outlet points of each rectifier; determining, by the Rack Supervising Unit (RSU), a temperature difference between the inlet and outlet temperatures of the rectifiers (R);proceeding with the charging process of the electrical energy storage device using the rectifiers (R) and activating a fan (110), if the temperature difference between the inlet and outlet temperatures is less than a predetermined temperature threshold; and terminating the charging process and notifying an operator of an overheating error, if the temperature difference between the inlet and outlet temperatures is equal to or greater than the predetermined temperature threshold.

16. A method for controlling coolant flow in a charging and interchange station, comprising: providing a solenoid valve (140) at an inlet of each rectifier stack; maintaining the solenoid valve (140) in an open condition when all rectifiers (R) in the rectifier stack are in working condition; closing the solenoid valve (140) to restrict coolant flow into the rectifier stack and terminating the charging process for that particular stack if one of the rectifiers in the stack fails; and notifying a corresponding pump (120) to reduce coolant flow rate when the solenoid valve (140) is closed.

17. A method for controlling coolant flow in a charging and interchange station for large capacity electrical energy storage devices, comprising: configuring a rectifier stack as a loop to behave as a single rectifier; maintaining a solenoid valve (140) at an inlet of the rectifier loop in an open condition when all rectifiers (R) in the loop are in working condition; keeping the solenoid valve (140) open to allow coolant flow into the rectifier stack at a derated charging condition while maintaining the flow rate, if one of the rectifiers in the loop fails; and closing the solenoid valve (140) to restrict coolant flow into the specific rectifier loop and terminating the charging process for that particular loop if all rectifiers in the loop fail.

18. The method as claimed in claim 17, further comprising: notifying a corresponding pump (120) to reduce coolant flow rate when the solenoid valve (140) is closed due to all rectifiers in the loop failing.

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