EV Charging Station Booster Switching for Wide DC Voltage Range
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Solution Overview
Problem
Charging stations for electric vehicles often require complex designs to accommodate a wide DC charging voltage range (200 V to 1000 V) to meet varying power and voltage demands, leading to inefficiencies, especially when high power is needed within a smaller voltage window.
Innovation Solution
The charging station employs at least two DC voltage sources, including a booster DC voltage source with a specific range (above 500 V) and a standard DC voltage source, where the booster source is selectively connected based on the vehicle's request, allowing for dynamic voltage adjustment and efficient power distribution without a shared DC/DC converter, enabling high-power charging within a narrower voltage range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple identical DC voltage sources are used to cover the full voltage range (200V-1000V), then the charging station can meet all CCS standard requirements, but the system complexity increases due to needing multiple voltage sources and switching mechanisms
Solution Approach 1:
The patent divides the DC voltage sources into two distinct segments: standard DC voltage sources (covering 200V-500V) and a booster DC voltage source (covering 500V-1000V). This segmentation allows each voltage source type to be optimized for its specific voltage range, reducing the overall system complexity while maintaining full voltage range coverage capability.
Solution Approach 2:
The control unit dynamically selects and switches between standard DC voltage sources and the booster DC voltage source based on the real-time voltage requirements of the electric vehicle. This dynamic switching mechanism enables the system to adapt to different charging scenarios without requiring all voltage sources to be simultaneously active, thereby reducing complexity.
2Device complexity
If a shared DC/DC converter is used for multiple DC voltage sources, then the device count is reduced, but the charging efficiency and power delivery capability deteriorates
Solution Approach 1:
The patent extracts the DC/DC converter function from being a shared component and instead integrates it directly into each DC voltage source module. Each DC voltage source (standard and booster) has its own dedicated DC/DC converter, which eliminates the bottleneck of a shared converter and allows each voltage source to independently and efficiently deliver power to the vehicle battery.
3Power
If the booster DC voltage source is always connected, then high-power charging capability is immediately available, but the energy waste and operational flexibility are reduced
Solution Approach 1:
The control unit dynamically controls the connection and disconnection of the booster DC voltage source based on the real-time charging requirements of the electric vehicle. When high-voltage charging is needed (above 500V), the booster source is connected; when standard voltage charging suffices, the booster source remains disconnected, avoiding unnecessary energy consumption and wear.
Solution Approach 2:
The system performs preliminary assessment of the vehicle's charging requirements through communication protocols before initiating charging. This allows the control unit to pre-determine whether the booster DC voltage source needs to be activated, optimizing energy usage from the start of the charging process.
Data Source
AI summary
A charging station for charging electric vehicles, having a connection unit for connecting the charging station to an electrical supply infrastructure and for supplying the charging station with electrical supply current; at least two direct current voltage sources, at least one of which is electrically coupled to the connection unit in order to be supplied with the electrical supply current by the connection unit, and which are configured to provide a proportionate electrical power for charging at least one electric vehicle by means of a direct current charging voltage which can be set in a respective direct current charging voltage range; a coupling unit for temporarily coupling the electric vehicle to at least one of the DC voltage sources; and a control unit for adjusting the DC charging voltages of the DC voltage sources and for connecting the DC voltage sources to the coupling unit depending on a voltage requirement.