BEV Charging Power Allocation for TRU Grid Overload Prevention

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Solution Overview

Problem

The rise of battery electric vehicles (BEVs) poses a challenge for electrical grid networks due to the large power draw required for transport refrigeration units (TRUs), which can lead to network overload and potential grid shutdowns, and existing systems lack smart management of standby operations.

Innovation Solution

A vehicle charging system with a master device connected to a primary grid network that manages power supply by communicating with slave devices in BEVs to regulate power allocation among TRUs, ensuring total power consumption remains below the grid's maximum capacity, and allows for priority requests and boost charging modes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple BEVs with TRUs are connected to the electrical grid simultaneously, then the power availability for charging increases, but the electrical grid network may experience overload and shutdown

Engineering Contradiction:
Improvepower availabilityVSAvoidgrid stability
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The system dynamically adjusts power allocation among multiple BEVs based on real-time grid conditions and charging priorities. The master device continuously monitors power consumption and modifies charging rates, allowing the system to adapt to changing load conditions and prevent grid overload while maximizing power utilization.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters by adjusting charging power levels for individual BEVs and TRUs. By modifying power allocation parameters dynamically rather than maintaining fixed charging rates, the system optimizes power distribution to match grid capacity and prevent overload conditions.

Inventive Principle:
Principle #35Parameter changes

2Temperature

If TRUs are operated at high power levels, then refrigeration effectiveness improves, but battery life is reduced and nominal power draw increases

Engineering Contradiction:
Improverefrigeration effectivenessVSAvoidbattery life
Core Design Contradiction:
TemperatureVSDuration of action of moving object

Solution Approach 1:

The system applies partial action by allocating power selectively to TRUs based on priority levels and actual refrigeration needs. Rather than operating all TRUs at maximum power simultaneously, the master device distributes power partially across multiple units, adjusting individual TRU power levels to meet cooling requirements while preventing excessive overall power draw that would harm battery life.

Inventive Principle:
Principle #16Partial or excessive action

3Productivity

If all TRUs are switched ON at the same timeframe, then refrigeration coverage is maximized, but the power draw creates negative impact on the network

Engineering Contradiction:
Improverefrigeration coverageVSAvoidpower draw
Core Design Contradiction:
ProductivityVSPower

Solution Approach 1:

The system segments the power allocation for multiple TRUs, dividing the total available power into controlled portions assigned to individual TRUs or BEVs. This segmentation allows refrigeration coverage to be maintained across multiple units while distributing power draw over time and among different circuits, preventing concentrated overload on the electrical network.

Inventive Principle:
Principle #1Segmentation

4Reliability

If priority requests are allowed for excess power, then critical refrigeration needs are met, but power allocation complexity increases

Engineering Contradiction:
Improvecritical function assuranceVSAvoidpower allocation logic
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The system implements feedback mechanisms where the master device monitors power consumption, grid conditions, and TRU operational status in real-time. This feedback enables dynamic adjustment of power allocation, allowing critical TRUs to receive priority power when needed while automatically adjusting non-critical allocations, thereby managing complexity through automated responsive control rather than static complex scheduling.

Inventive Principle:
Principle #23Feedback

Data Source

PatentEP4378745B1Method and system for managing power supply during charging operation of bevs
Publication Date: 2026.03.25 CARRIER CORP
  • EP4378745B1 patent drawingFigure 1A
  • EP4378745B1 patent drawingFigure 1B
  • EP4378745B1 patent drawingFigure 2

AI summary

A method (1100) for managing power supply during charging operation of BEVs. The method includes establishing a communication (503,507,511;503B,507B,511B) with each of the slave devices (407;407B) installed in the BEVs (1101) and receiving input data from the slave devices (407;407B) in real-time via a communication interface (501;501B) (1103). The method further includes calculating a total power currently utilized by a plurality of TRUs based on the received input data (1105) and determining a probability whether the calculated total power exceeds a maximum allowed power provided by the primary grid network (401;401B) during the charging operation in case a new charging request is received from a new slave device (407;407B) (1107). Thereafter, the method further includes regulating, based on the determined probability, a power allocation of a group of TRUs among the plurality of the TRUs such that the total calculated power remains below a saturation point of the maximum allowed power (1109).