Dual Voltage Charging Station with Dynamic Power Module Configuration
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Solution Overview
Problem
Current DC fast charging stations lack the capability to accommodate both electric vehicles with DC battery voltages in the 200 V-500 V range and those in the 400 V-1000 V range, leading to inefficiencies in charging time and infrastructure design, such as high current requirements and mechanical flexibility issues.
Innovation Solution
A dual voltage range charging station with a configuration selection unit that connects DC power modules in series or parallel configurations, allowing for automatic adjustment of voltage ranges from 200 V to 1000 V, using multiple DC power modules and switching units to maintain consistent electrical power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If DC fast charging stations are designed to deliver higher electrical power for shorter charging sessions, then charging speed is improved, but cable thickness and weight increase significantly
Solution Approach 1:
The charging station employs dynamic voltage adjustment capability, allowing it to adapt between 200V-500V and 400V-1000V ranges based on vehicle requirements. This dynamic operation enables the system to optimize current levels and reduce cable stress during high-power charging operations
Solution Approach 2:
The system changes operational parameters by switching between different voltage ranges (200V-500V for conventional vehicles, 400V-1000V for advanced vehicles). This parameter change allows the same infrastructure to serve multiple vehicle types while managing current requirements and cable specifications
2Loss of time
If DC fast charging stations are designed to deliver higher electrical power for shorter charging sessions, then charging time is reduced, but cable heating increases significantly
Solution Approach 1:
The charging station dynamically adjusts voltage parameters to match vehicle battery requirements, operating in 200V-500V or 400V-1000V ranges. This enables efficient power delivery with optimized current levels, reducing resistive heating in cables during fast charging operations
Solution Approach 2:
The system replaces mechanical cable sizing solutions with electrical parameter adjustment. Instead of using thicker cables to handle higher currents, the system uses voltage range switching to control current levels and reduce heating effects
3Device complexity
If a single charging station design is used for all electric vehicles, then device complexity is reduced, but adaptability to different voltage ranges is lost
Solution Approach 1:
The charging station is designed with multi-functionality to accommodate both conventional (200V-500V) and advanced (400V-1000V) electric vehicles using the same infrastructure. The system provides universal service through voltage range switching capability
Solution Approach 2:
The charging station incorporates dynamic configuration capability, allowing it to adapt its operational characteristics based on the connected vehicle's voltage requirements. This dynamic adaptation enables a single design to serve multiple vehicle types without requiring separate charging infrastructures
4Productivity
If battery voltage is increased to 400V-1000V for very fast charging, then current requirements are reduced, but compatibility with existing 200V-500V vehicles is lost
Solution Approach 1:
The charging station provides universal compatibility with both conventional (200V-500V) and advanced (400V-1000V) electric vehicles through a single infrastructure design. The system automatically or manually configures the appropriate voltage range to match the connected vehicle
Solution Approach 2:
The system changes its operational voltage parameters based on the vehicle type being charged. By switching between 200V-500V and 400V-1000V ranges, the same charging station can optimize performance for different vehicle architectures while maintaining broad compatibility
Data Source
AI summary
A power circuit for a dual voltage range charging station is disclosed. The power circuit comprises a first group comprising at least one DC power module, the first group having a first corresponding terminal and a second corresponding terminal; a second group comprising at least one DC power module, the second group having a first corresponding terminal and a second corresponding terminal; a configuration selection unit operatively connected to the first corresponding terminal of the first group, to the second corresponding terminal of the first group, to the first corresponding terminal of the second group and to the second corresponding terminal of the second group; wherein in a first configuration, the first corresponding terminal of the first group is operatively connected to the first corresponding terminal of the second group and the second corresponding terminal of the second group is operatively connected to the second corresponding terminal of the second group and a first given voltage is provided between the first corresponding terminal of the first group and the second corresponding terminal of the second group and further wherein in a second configuration, the second corresponding terminal of the first group is operatively connected to the first corresponding terminal of the second group and a second given voltage greater than the first given voltage is provided between the first corresponding terminal of the first group and the second corresponding terminal of the second group.