Prefabricated EV Charging Chassis for Scalable Power Distribution
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Solution Overview
Problem
Current electric vehicle (EV) charging station installations are complex, labor-intensive, and costly, with limited scalability and high maintenance requirements due to underground cabling and peak demand charges, necessitating a modular and expandable solution for efficient deployment and energy management.
Innovation Solution
A modular, prefabricated EV charging station chassis with a simplified installation method using a single underground power cable and transformer, enabling offsite assembly by trained labor and easy expansion, incorporating energy storage and smart charging protocols to minimize peak demand and maintenance, along with optional features like solar power and weather protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional EVSE stations are installed with independent power cables and underground cabling for each charging post, then reliable power distribution is achieved, but installation complexity and labor costs increase substantially
Solution Approach 1:
The charging station is divided into modular charging posts that can be independently configured and installed. Each module contains integrated power distribution components, allowing the system to be segmented into standardized units that simplify installation while maintaining reliable power delivery to each charging location.
Solution Approach 2:
Multiple power distribution functions are merged into a centralized power distribution unit that serves all charging posts. This consolidation eliminates the need for separate underground cabling runs to each post, reducing installation complexity while ensuring reliable power delivery through a unified distribution system.
2Manufacturing precision
If trained labor force through EVITP is used for installation, then installation quality is ensured, but the number of stations that can be installed is limited by the limited number of trained individuals
Solution Approach 1:
The charging station components are pre-assembled and pre-configured in a controlled manufacturing environment before delivery to the installation site. This preliminary assembly ensures installation quality through factory-tested connections while enabling rapid deployment by trained personnel who only need to perform final site installation rather than complex assembly tasks.
3Reliability
If underground cable design is used for power and communication distribution, then cable protection is achieved, but maintenance and upgrade difficulty increases
Solution Approach 1:
An above-ground equipment enclosure serves as an intermediary housing for power distribution and communication equipment. This enclosure provides protected connections while remaining accessible for maintenance and upgrades, eliminating the need to access underground cables for routine servicing while still protecting electrical connections from environmental damage.
4Power
If EVSE equipment adds considerable peak demand to commercial electrical service, then charging capacity is provided, but demand charges from utility companies increase
Solution Approach 1:
The charging station implements smart charging schedules that distribute power delivery across different time periods. By staggering charging operations and utilizing off-peak hours for energy storage charging, the system maintains adequate charging capacity while reducing peak demand charges through periodic energy delivery rather than continuous high-power draw.
Solution Approach 2:
Energy storage systems provide continuous power delivery to charging posts by storing energy during off-peak hours and discharging during peak periods. This continuity of useful action ensures charging capacity is always available while shifting the actual power draw from utility lines to off-peak periods, thereby reducing demand charges.
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 solution reduces installation costs, accelerates deployment, minimizes site disturbance, and decreases peak demand charges by up to 80% through efficient energy management and smart charging, while allowing for flexible upgrades and expansions without extensive site work.
Implementation Method 1
utilizing one or more energy storage systems (i.e., batteries) that are charged at non-peak times (and rates)
Implementation Method 2
photovoltaic elements. For example, solar photovoltaic roofing and other photovoltaic components may be provided to supply energy
Data Source
AI summary
A modular, expandable, prefabricated chassis for EV charging stations useful in supporting a plurality of EVSE charging posts, including a support housing through which power and communications cabling is channeled, and a connection cabinet affixed to the support housing for receiving power from a utility, and disbursing it through the cabling. Also, a modular, portable EV charging station, including a chassis and a plurality of EVSE charging posts affixed to the support housing, wherein power cables, the electrical wire and the communications cabling from the support housing are electrically or communicatively coupled with the EVSE charging post. Also, a method of installing an EV charging station at a site, the method including the transport of a fully assembled EV charging station to a site, positioning the EV charging station on a solid pad provided at the site, and connecting utility lines to the connection cabinet of the EV charging station.