DC EV Charging Station With Battery Buffering for Weak Grids

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Solution Overview

Problem

The lack of fast-charging infrastructure, particularly in weak AC distribution grids, restricts the adoption of electric vehicles due to range anxiety and integration issues, leading to protection system and voltage regulation problems.

Innovation Solution

A battery-enabled, direct current (DC) electric vehicle charging station with a controller that monitors and controls power flow from multiple sources, including battery energy storage systems and renewable energy, to manage charging demands and prevent operating condition violations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If EV fast-charging stations are integrated into weak AC distribution grids, then electric vehicle charging capability is provided, but protection system issues and voltage/frequency regulation problems occur

Engineering Contradiction:
ImproveEV charging capabilityVSAvoidgrid stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent introduces an intermediary energy storage system and DC bus architecture between the weak AC grid and the EV fast-charging loads. This intermediary DC energy storage system acts as a buffer that decouples the fast-charging station from the weak AC grid, allowing high-power charging operations without directly impacting grid stability. The DC-DC converters and control systems manage power flow to prevent voltage and frequency regulation issues while enabling fast charging capability.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Productivity

If multiple EV fast-charging stations operate simultaneously, then charging infrastructure capacity increases, but weak AC distribution grids cannot support the load

Engineering Contradiction:
Improvecharging infrastructure capacityVSAvoidgrid power capacity
Core Design Contradiction:
ProductivityVSPower

Solution Approach 1:

The patent implements preliminary energy storage and power management actions by incorporating DC energy storage systems that can pre-charge or buffer power before EV fast-charging operations begin. The controller monitors and manages power flow in advance, allowing multiple charging stations to operate simultaneously by drawing from stored energy rather than directly from the weak AC grid, thus avoiding power capacity limitations.

Inventive Principle:
Principle #10Preliminary action

3Adaptability or versatility

If AC to DC conversion is performed at each charging station, then charging flexibility is improved, but system complexity and loss increase

Engineering Contradiction:
Improvecharging flexibilityVSAvoidsystem complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the AC to DC conversion function into a centralized architecture where a common DC bus and energy storage system serve multiple charging stations. Instead of each station having independent AC-DC converters, the system consolidates conversion infrastructure, reducing overall device complexity and minimizing conversion losses while maintaining charging flexibility through the DC bus distribution network.

Inventive Principle:
Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The DC architecture enables efficient and scalable fast charging, mitigating grid voltage regulation issues and supporting large-scale electric vehicle adoption by stabilizing power distribution.

Implementation Method 1

a battery-enabled, direct current (DC) electric vehicle charging station with a controller that monitors and controls power flow from multiple sources, including battery energy storage systems

Methodology Applied
Scientific EffectBattery (electricity): Battery (electricity)

Data Source

PatentUS20250381874A1Battery-enabled, direct current, electric vehicle charging station, method and controller therefor
Publication Date: 2025.12.18 ECAMION
  • US20250381874A1 patent drawing
  • US20250381874A1 patent drawing
  • US20250381874A1 patent drawing

AI summary

An electric vehicle charging station comprises a direct current (DC) bus configured to receive DC power from multiple power sources including at least one battery energy storage system (BESS); at least one electric vehicle charging stall connected to the DC bus and configured to charge an electric vehicle load; and a controller configured to monitor and control power flow from the DC bus to the at least one electric vehicle charging stall and to monitor and control power flow between the BESS and the DC bus.