EV Fast Charger Voltage-Range Overlap for Stable Battery Charging
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Solution Overview
Problem
Existing quick charging stations for electric vehicles lack flexibility in output voltage during charging, as they are not designed to handle varying battery voltages efficiently, leading to potential inefficiencies and incomplete charging.
Innovation Solution
The quick charging station is redesigned to allow overlapping output voltage areas for its functional states, enabling the control unit to select the appropriate state based on the actual and target charging voltages, ensuring efficient charging across different battery tensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the power converter arrangement switches between functional states during charging, then the output voltage flexibility is improved, but the system stability deteriorates due to abrupt potential changes on output capacitors
Solution Approach 1:
The patent implements dynamic voltage range allocation where the first functional state covers a lower voltage range (e.g., 200V-500V) and the second functional state covers a higher voltage range (e.g., 400V-920V), with overlapping ranges that allow seamless transition. The control unit dynamically selects which functional state to use based on real-time battery voltage measurements, ensuring continuous stable operation without abrupt potential changes.
Solution Approach 2:
The patent segments the overall voltage conversion function into two distinct functional states with different output voltage ranges. Each functional state is optimized for specific voltage requirements, with the first state handling lower voltages and the second state handling higher voltages. This segmentation allows the system to maintain stability within each segment while providing overall voltage flexibility.
2Device complexity
If the output voltage ranges of functional states are made non-overlapping, then the device complexity is reduced, but the adaptability to different battery voltages deteriorates
Solution Approach 1:
The patent establishes predetermined overlapping voltage ranges for the two functional states during the design phase. The first functional state is configured with an output voltage range that extends into the lower portion of the second state's range, creating an overlap region. This preliminary configuration ensures that batteries with voltages in the overlap region can be charged without requiring complex real-time range adjustment, simplifying the control logic while maintaining broad adaptability.
3Productivity
If the functional state is selected based only on current voltage, then the charging efficiency is improved, but the completeness of charging deteriorates when battery voltage exceeds the functional state range
Solution Approach 1:
The control unit continuously monitors the battery voltage during charging and uses this feedback to determine the appropriate functional state. When the battery voltage enters the overlap range, the control unit evaluates whether to switch between functional states to ensure the battery can be charged to its full capacity. This feedback mechanism prevents incomplete charging while maintaining efficiency by selecting the most appropriate functional state for the current battery condition.
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
This design enhances the flexibility and efficiency of the charging process by allowing the quick charging station to adapt to varying battery voltages, ensuring complete and efficient charging of electric vehicles.
Implementation Method 1
a power converter arrangement (4) for converting an alternating voltage as the input voltage of the rapid charging station (1) into a direct voltage as the output voltage of the rapid charging station (1)
Implementation Method 2
the DC/DC converter operates as a charge pump on the output side... the output voltage is doubled (ideally, without considering losses)
Data Source
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AI summary
The invention relates to a fast charging station for electric vehicles, wherein the fast charging station (1) has a control unit (5) and a power converter arrangement (4) for converting an alternating voltage as input voltage of the fast charging station (1) into a direct voltage as output voltage of the fast charging station (1), wherein the power converter arrangement (4) has two mutually exclusive operating states, a first and a second operating state, which can be set by the control unit (5) on the power converter arrangement (4), wherein the power converter arrangement (4) covers different output voltage ranges in the operating states, wherein the control unit (5) evaluates communication with an electric vehicle connected to the fast charging station (1) and/or measured values relating to the electric vehicle and thus obtains battery parameters and sets the operating state depending on the battery parameters.It is proposed that the output voltage ranges of the two operating states overlap in an overlap region (9), that the battery parameters include an actual charging voltage (7), and that when the actual charging voltage (7) is in the overlap region (9), the control unit (5) selects one of the operating states to charge the electric vehicle, depending on the battery parameters.