EV Charging Control Unit Reactive Power Management

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Solution Overview

Problem

Existing electrical charging systems for motor vehicles face issues with reactive power transmission, network asymmetries, and disconnection due to excessive loads during single-phase or three-phase energy transfer, particularly in private households and public charging stations.

Innovation Solution

A control unit with a communication interface is used to interchange data with the charging station, allowing for controlled energy transfer by limiting reactive power and balancing network loads, enabling symmetrical energy distribution and preventing disconnection through phase management and authentication.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a transformer converts electrical energy from alternating current to direct current during charging, then electrical energy can be transmitted to the motor vehicle, but reactive power is transmitted and phase shift occurs between electrical current and voltage

Engineering Contradiction:
Improveelectrical energy transmissionVSAvoidreactive power transmission
Core Design Contradiction:
Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The control unit continuously monitors the charging process and adjusts the electrical converter operation based on feedback signals. It receives data from the charging station about network conditions and actively controls the converter to minimize reactive power transmission while maintaining efficient DC conversion, thereby resolving the contradiction between energy transmission and reactive power loss.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The control unit dynamically changes operating parameters of the electrical converter during the charging process. By adjusting conversion ratios, switching frequencies, and other parameters based on real-time conditions, the system optimizes the balance between transmitting necessary electrical energy and minimizing reactive power losses.

Inventive Principle:
Principle #35Parameter changes

2Use of energy by moving object

If single-phase transmission of electrical energy is used to charge the motor vehicle, then electrical energy can be supplied, but network asymmetries or neutral point shift may occur

Engineering Contradiction:
Improveelectrical energy supplyVSAvoidnetwork stability
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The control unit receives feedback information from the charging station about the charging phase configuration and network conditions. Based on this feedback, it actively adjusts the charging process to maintain network stability, preventing neutral point shifts and asymmetries while ensuring continuous electrical energy supply to the motor vehicle.

Inventive Principle:
Principle #23Feedback

3Power

If excessively high electrical reactive powers occur during charging, then charging may proceed at high power, but disconnection of electrical energy transmission may occur

Engineering Contradiction:
Improvecharging powerVSAvoidcharging connection stability
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The control unit takes preliminary action by proactively monitoring and limiting reactive power transmission before excessive levels can cause disconnection. It preemptively adjusts the electrical converter operation to maintain reactive power within safe limits, thereby preventing charging disconnection while still enabling high power charging when conditions permit.

Inventive Principle:
Principle #9Preliminary anti-action

Solution Approach 2:

The control unit continuously receives feedback about reactive power levels from the charging station and actively adjusts the charging process in real-time. This closed-loop control ensures that charging power can be maintained at high levels when appropriate while automatically reducing power when reactive power approaches dangerous thresholds, preventing disconnection.

Inventive Principle:
Principle #23Feedback

4Reliability

If data interchange between charging apparatus and charging station is implemented, then controlled energy transfer is enabled, but device complexity increases

Engineering Contradiction:
Improveenergy transmission controlVSAvoidcommunication interface
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The communication interface is integrated into the existing charging system infrastructure, serving multiple functions including data exchange for control, authentication, and monitoring. By making the communication system multi-functional rather than adding dedicated separate systems, the patent achieves reliable controlled energy transfer while minimizing the increase in device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 ensures reliable and robust electrical energy transmission to motor vehicles by controlling energy withdrawal, reducing the risk of network overload and disconnection, and facilitating efficient energy distribution across multiple phases.

Implementation Method 1

an electrical converter that is connected to the electrical connection for interchanging electrical energy with the charging station via the electrical connection and to convert the electrical energy

Methodology Applied
Scientific EffectElectrical energy conversion:

Data Source

PatentUS10500967B2Electrical charging apparatus, electrical charging station and method for controlling an electrical charging apparatus
Publication Date: 2019.12.10 DR ING H C F PORSCHE AG
  • US10500967B2 patent drawing

AI summary

An electrical charging apparatus (10) for charging an electrical energy store of a motor vehicle (12) has an electrical connection (16) to electrically connect the charging apparatus (10) to a charging station (14) and to interchange electrical energy with the charging station (14). An electrical converter (18) is connected to the electrical connection (16) to interchange the electrical energy with the charging station (14) via the electrical connection (16) and to convert the electrical energy. A control unit (20) is connected to the electrical converter (18) to control the interchange of the electrical energy. A communication interface (22) is assigned to the control unit (20) and is designed to interchange data (34) with the charging station (14). The control unit (20) is designed to control the interchange of the electrical energy on the basis of the data.